Textiles and articles and processes for making the same

ABSTRACT

Films, fibers, filaments, yarns and textiles including thermoplastic elastomeric compositions are described, as are methods of making the films, fibers, filaments, yarns and textiles. These films, fibers, filaments, yarns and textiles can be used to make articles of apparel, footwear, and sporting equipment. When thermoformed, the thermoplastic elastomeric compositions can impart abrasion resistance, traction, and other advantageous properties to the articles. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of, co-pending U.S.provisional application entitled “ TEXTILES AND ARTICLES AND PROCESSESFOR MAKING THE SAME” having Ser. No. 62/882,008, filed Aug. 2, 2019, thecontents of which are incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure is directed to textiles, components of articles,and articles, such as articles of apparel, articles of footwear, andarticles of sporting equipment. More specifically, the presentdisclosure is directed to textiles which include a coated yarn, andcomponents of articles, and articles which comprise the textiles. Thepresent disclosure is also directed to methods of making the textiles,components and articles described herein.

BACKGROUND

Traditionally, vulcanized rubber has been used to provide traction andabrasion resistance to articles such as apparel, footwear and sportingequipment. The need to vulcanize the rubber at high temperatures and/orpressures typically makes it necessary to form a separate vulcanizedrubber component which is then affixed to the article using adhesives orstitching or both, as other components of the article may not be able towithstand the temperatures and/or pressures required by thevulcanization process. Alternatively, in footwear uppers, crosslinkedpolyurethanes can be used as durable covering layers, synthetic leathertextiles, or laminate film layers. A need remains for new materials thatcan provide the same types of protection as vulcanized rubber orcrosslinked polyurethane in addition to traction or abrasion resistanceor both, and for new ways of incorporating these materials intoarticles.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the present disclosure will be readily appreciatedupon review of the detailed description, described below, when taken inconjunction with the accompanying drawings.

FIG. 1A is a top and side perspective view of an article of footwear inaccordance with aspects of the present invention.

FIG. 1B is a bottom and side perspective view of the article of footwearof FIG. 1A, in accordance with aspects of the present invention.

FIG. 1C is a top and side perspective view of an alternative aspect ofthe article of footwear of FIG. 1A in accordance with aspects of thepresent invention.

FIG. 2A is a side view of an article of apparel, primarily illustratingan elbow patch, in accordance with aspects of the present invention.

FIG. 2B is a close-up view of the elbow patch of the article of apparelof FIG. 2A in accordance with aspects of the present invention.

FIG. 3 is a plan view of a schematic depiction of a textile having threetypes of textile zones, in accordance with aspects of the presentinvention.

FIGS. 4A-4J depict exemplary knit structures in accordance with aspectsof the present invention.

FIG. 5A is a schematic representation of three interconnected courses ofloops with the middle course of loops being formed of a different yarnthan the outer courses of loops, in accordance with aspects of thepresent invention.

FIG. 5B is a schematic representation of the interconnected courses ofloops of FIG. 5A after being exposed to a thermoforming process, andshowing the middle course of loops being transformed into a componentincluding re-flowed polymeric composition which no longer has theconfiguration of a yarn upon thermoforming, where the two outer coursesof loops remain in the configuration of yarns, in accordance withaspects of the present invention.

FIG. 6 is a schematic representation of a cross-section of the componentincluding re-flowed polymeric composition of FIG. 5B, and showing aportion of a yarn from one of the outer courses of loops beingencapsulated within the re-flowed polymeric composition, in accordancewith aspects of the present invention.

FIG. 7A shows a textile comprising coated yarns according to the presentdisclosure prior to thermoforming, while FIG. 7B shows the same textileafter thermoforming. FIG. 7C shows a textile comprising coated yarns andan additional yarn according to the present disclosure prior tothermoforming, while FIG. 7D shows the same textile after thermoforming.FIG. 7E shows a textile comprising coated yarns on both a top and bottomface of the textile and incorporating coated yarns in the core of thetextile prior to thermoforming, while FIG. 7F shows the same textileafter thermoforming.

FIGS. 8A-8M show various articles of footwear, apparel, athleticequipment, container, electronic equipment, and vision wear inaccordance with the present disclosure.

FIGS. 8N(a)-8Q(e) illustrate additional details regarding differenttypes of footwear.

DETAILED DESCRIPTION

Thermoplastic elastomers have been identified which can be incorporatedinto polymeric compositions that provide levels of abrasion resistance,traction, or both, making them suitable for use in articles whereabrasion resistance or traction are desirable, such as articles ofapparel, footwear and sporting equipment. In many cases, the level ofabrasion resistance, traction, or both provided by these polymericcompositions are equivalent to or better than standard vulcanized rubbercompositions used in the manufacture of footwear, apparel and sportingequipment. Unlike vulcanized rubber, due to the thermoplastic nature ofthese polymeric compositions, and their properties in the solid andmolten state, it is possible to readily form them into coated yarnswhich have suitable properties for use in industrial scale knitting orweaving equipment. These properties result in yarns that can readily beincorporated into various articles including textiles using conventionalmanufacturing processes such as knitting and weaving, as well asindustrial scale processes for making non-woven textiles. Also unlikevulcanized rubber, these textiles and articles into which these textilesare incorporated can then, in turn, be thermoformed in a manner whichreflows the polymeric composition of the coated yarns and creates anabrasion resistant or high traction surface on the textile or articleunder conditions which do not damage other components of the textile orarticle, such as, for example, other yarns, other textiles, foams,molded resin components, etc. The polymeric compositions disclosedherein retain their favorable properties after repeated cycles ofmelting and re-solidifying, making it possible to first use them to coatyarns, and then thermoform the yarns to create re-flowed structureswhich retain their abrasion resistance, traction properties, or both.Additionally, due to the compatibility of these polymeric compositionswith other materials commonly used to make articles of footwear, apparelas sporting equipment such as polyurethanes, polyesters and polyamides,the thermoforming process may securely bond the polymeric composition tothe other components, making it unnecessary to use adhesives orstitching to attach the textiles to the other component, therebyreducing the number of manufacturing steps and avoiding the use of toxicprimers and adhesives.

Additionally, polymeric compositions have been found which are capableof being extruded as coatings onto core yarns in amounts and at ratesneeded for commercial yarn production, and which produce yarns havingthe balance of elongation, strength, and shrinkage necessary for use incommercial high-speed knitting equipment, either as a knitting yarn oran inlay yarn.

The coated yarns disclosed herein include a core yarn and a firstcoating. The core yarn can comprise a conventional monofilament ormultifilament yarn such as a commercially available polyester orpolyamide yarn having properties (such as denier and tenacity)sufficient for it to be manipulated by industrial-scale knittingequipment. The first coating of the coated yarn comprises a polymericcomposition which is a thermoplastic elastomeric composition. While itis possible to extrude a polymeric composition which is a thermoplasticelastomeric composition and form fibers, filaments, yarns or filmsdirectly from the polymeric composition, due to its elastomericproperties, these forms of the polymeric composition will have highlevels of stretch and heat shrinkage. This means the fibers, filaments,yarns or films may tend to stretch around machine guides rather thanslide past them, and may tend to shrink at the temperatures commonlyencountered in industrial-scale knitting and weaving equipment. However,by applying the polymeric composition as a coating onto a core yarnwhich is suitable to be mechanically manipulated, the resulting coatedyarn retains the tenacity and stretch resistance of the core yarn, whilealso providing an outer surface having superior traction and abrasionresistance provided by the polymeric composition due to its elastomericproperties. For example, it has been found that a 150 denier core yarnhaving a tensile strength of at least 1 kilogram·force at break and lessthan 20 percent strain to break, and heat shrink of less than 20 percentcan be coated with the polymeric composition to a nominal average outerdiameter of up to about 1.0 millimeter, and retain its ability to beknit or inlaid using commercial flat-knitting equipment. Due to theability to use this yarn on industrial-scale equipment, this coated yarnalso opens up possibilities for new methods of manufacturing which allowplacement of the polymeric composition within textiles and articlescomprising the textiles at greater levels of specificity in terms ofboth location and amount as compared to conventional manufacturingprocesses.

Additionally, the thermoplastic nature of the polymeric compositionmakes it possible to melt the composition and use it to coat the coreyarn when the melting temperature of the polymeric composition issufficiently lower than the deformation temperature of the core yarn, aswell as to subsequently thermoform the textile to create a thermoformednetwork comprising both the core yarn and the re-flowed andre-solidified polymeric composition consolidating the core yarn. Whenthe textile includes one or more second yarn in addition of the coatedyarn, the thermoformed network of yarns (i.e., the core yarn and the oneor more second yarn) are consolidated by the re-flowed and re-solidifiedpolymeric composition. The presence of the re-flowed and re-solidifiedpolymeric composition can serve one or more functions within thethermoformed textile, such as controlling the level of stretch withinthe entire textile or just within a region of the textile, forming askin having high abrasion-resistance and/or traction across an entiresurface of the textile or just within a region of the textile, improvingwater resistance of an entire surface of the textile or just within aregion of the textile, or bonding all of the textile or just a region ofthe textile to a substrate. Use of the coated yarn in these textiles canalso reduce the number of different materials required to form anarticle. The coating of the coating yarn, when thermoformed, can form askin on a surface of the textile. Alternatively or additionally, thecoating of the coating yarn, when thermoformed, can act as a bondingagent, either to bond yarns together within the textile, or to bondother elements to a surface of the textile. Conventionally, a separatefilm layer is required to form a skin on a textile, or a separateadhesive layer is required to bond yarns within a textile or to bondother elements to the surface of a textile. For example, in aconventional article of footwear, the upper may incorporate elementssuch as multiple layers of textiles, films and/or cables to limitstretch of regions of the upper, separate elements or layers oftextiles, films or rubber to increase abrasion resistance of the upper,separate elements or layers of rubber to form areas of high traction onan outsole, and separate layers of adhesives or cements to bond thevarious elements or layer to each other. The use of the thermoformedtextiles described herein can replace one or more of the separateelements, reducing waste and simplifying manufacturing processes whileimproving recyclability of the articles.

As will be discussed below, in one aspect, the thermoformed textilescomprising coated yarns as described herein can be used to form uppersfor articles of footwear. In a particular aspect, the thermoformednetwork of the thermoformed textile can form an externally-facingsurface of an upper, such as an upper for a global football boot.Unexpectedly, the thermoformed network formed by thermoforming thetextiles has superior properties for ball contact, in that theproperties of the thermoformed network can be equal to or superior tothose of kangaroo skin leather in terms of the spin rate imparted to theball by the upper when kicking the ball. For example, it has been foundthat using polymeric compositions having a Durometer hardness of about65 to about 85 results in uppers with improved ball spin rates. Upperscomprising the textiles described herein have also been found to beequivalent to or superior to those of synthetic leather or knit upperscoated with a DURAGON skin in terms of traction under wet and dryconditions. Additionally, as uppers formed from the thermoformedtextiles use fewer components in the manufacturing process and do notrely on animal-based materials, their manufacture produces less wastewhile using more sustainable materials which can be recycled.

In another aspect, the thermoformed textiles comprising coated yarns asdescribed herein can be used to form outsoles for articles of footwear.In a particular aspect, the thermoformed network of the thermoformedtextile can form an externally-facing surface of an outsole, including aground-facing surface or a ground-contacting surface of an outsole.Conventionally, cross-linked polymeric compositions such as vulcanizedrubber or cross-linked polyurethanes have been used for outsoles due totheir high levels of abrasion resistance and traction. Unexpectedly, ithas been found that the use of the textiles including coated yarnscomprising polymeric coatings disclosed herein can be used to replacecross-linked polymeric compositions as outsole materials, whileretaining the high levels of traction and abrasion resistance requiredfor outsoles. Specifically, by using the coated yarns described hereinwhich can be used in commercial knitting machines, it is possible tocreate thermoformed networks which provide levels of abrasion resistanceand traction equivalent to, and in come cases superior to, conventionaloutsole materials. As these thermoformed networks can be formed at lowertemperatures and pressures as compared to conventional vulcanizationprocesses, it is possible to thermoform the textiles while they are incontact with other components such as other textiles or molded resincomponents, thereby reducing energy consumption and reducingmanufacturing steps.

The present disclosure is directed to a textile comprising a firstnetwork of yarns including a first coated yarn, wherein the first coatedyarn comprises a core yarn and a first coating, wherein the firstcoating comprises a first polymeric composition. The first polymericcomposition is a thermoplastic elastomeric composition, and comprises atleast one thermoplastic elastomer. In some aspects, the first network ofyarns further comprises one or more second yarns. The one or more secondyarns can be coated yarns, or can be uncoated yarns. The textile can bea knit textile, and the first network of yarns can includeinterconnected loops of the first coated yarn, or can include the firstcoated yarn inlaid in a knit structure formed of interconnecting loopsof one or more second yarns.

The present disclosure is directed to a textile, comprising: a firstnetwork of yarns including a first coated yarn, the first coated yarncomprising a first core yarn and a first coating including a firstpolymeric composition disposed on at least a portion of an outer surfaceof the first core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition.

The present disclosure is directed to a textile, comprising: athermoformed network of yarns, the thermoformed network comprising afirst core yarn and a first polymeric composition, wherein the firstpolymeric composition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition.

The present disclosure is directed to an upper for an article offootwear, comprising: a textile, wherein the textile comprises a firstnetwork of yarns including a first coated yarn, the first coated yarncomprising a first core yarn and a first coating including a firstpolymeric composition disposed on at least a portion of an outer surfaceof the first core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition.

The present disclosure is directed to an upper for an article offootwear, comprising: a first textile comprising a thermoformed networkof yarns comprising a first core yarn and a first polymeric composition,wherein the first polymeric composition consolidates the thermoformednetwork of yarns by surrounding at least a portion of the first coreyarn and occupying at least a portion of spaces between yarns in thethermoformed network of yarns, and wherein the first polymericcomposition is a thermoplastic elastomeric composition.

The present disclosure is directed to an outsole for an article offootwear, comprising: a textile comprising a thermoformed network ofyarns comprising a first core yarn and a first polymeric composition,wherein the first polymeric composition consolidates the thermoformednetwork of yarns by surrounding at least a portion of the first coreyarn and occupying at least a portion of spaces between yarns in thethermoformed network of yarns, and wherein the first polymericcomposition is a thermoplastic elastomeric composition.

The present disclosure is directed to a method of making a textile, themethod comprising: forming a first network of yarns including a firstcoated yarn, the first coated yarn comprising a first core yarn and afirst coating including a first polymeric composition disposed on atleast a portion of an outer surface of the first core yarn, wherein thefirst polymeric composition is a thermoplastic elastomeric composition.

The present disclosure is directed to a method of making a textile, themethod comprising: thermoforming a first textile comprising a firstnetwork of yarns including a first coated yarn, the first coated yarncomprising a first core yarn and a first coating including a firstpolymeric composition disposed on at least a portion of an outer surfaceof the first core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition; thereby forming a thermoformednetwork of yarns comprising the first core yarn and the first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns.

The present disclosure is directed to a method of making an upper for anarticle of footwear, the method comprising: affixing a first textile toa second component, wherein the first textile comprises a first networkof yarns including a first coated yarn, the first coated yarn comprisinga first core yarn and a first coating including a first polymericcomposition disposed on at least a portion of an outer surface of thefirst core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition.

The present disclosure is directed to a method of making an upper for anarticle of footwear, the method comprising: thermoforming an uppercomprising a first textile, wherein the first textile comprises a firstnetwork of yarns including a first coated yarn, the first coated yarncomprising a first core yarn and a first coating including a firstpolymeric composition disposed on at least a portion of an outer surfaceof the first core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition; and wherein the thermoformingcomprises melting, reflowing, and re-solidifying the first polymericcomposition within the first textile, forming a thermoformed textilecomprising a thermoformed network of yarns comprising the first coreyarn and the first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns.

The present disclosure is directed to a method of making an upper for anarticle of footwear, the method comprising: affixing a first textile toa second component, wherein the first textile comprises a thermoformednetwork of yarns comprising a first core yarn and a first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns, and wherein the first polymericcomposition is a thermoplastic elastomeric composition.

The present disclosure is directed to a method for making an outsole foran article of footwear, the method comprising thermoforming a firsttextile; wherein the thermoforming comprises thermoforming the textileon a sole component, or on a molding surface, optionally wherein themolding surface is a molding surface having the dimensions of theoutsole; wherein the first textile comprises a first network of yarnsincluding a first coated yarn, the first coated yarn comprising a firstcore yarn and a first coating including a first polymeric compositiondisposed on at least a portion of an outer surface of the first coreyarn, wherein the first polymeric composition is a thermoplasticelastomeric composition; and wherein the thermoforming comprisesmelting, reflowing, and re-solidifying the first polymeric compositionwithin the first textile, forming a thermoformed textile comprising athermoformed network of yarns comprising the first core yarn and thefirst polymeric composition, wherein the first polymeric compositionconsolidates the thermoformed network of yarns by surrounding at least aportion of the first core yarn and occupying at least a portion ofspaces between yarns in the thermoformed network of yarns.

The present disclosure is directed to a method of making an article,comprising: affixing a first textile to a second component, wherein thefirst textile comprises a first network of yarns including a firstcoated yarn, the first coated yarn comprising a first core yarn and afirst coating including a first polymeric composition disposed on atleast a portion of an outer surface of the first core yarn, wherein thefirst polymeric composition is a thermoplastic elastomeric composition.

The present disclosure is directed to a method of making an article, themethod comprising: thermoforming a first textile, wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition; andwherein the thermoforming comprises melting, reflowing, andre-solidifying the first polymeric composition within the first textile,forming a thermoformed textile comprising a thermoformed network ofyarns comprising the first core yarn and the first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns.

The present disclosure is directed to a method of making an article, themethod comprising: affixing a first textile to a second component,wherein the first textile comprises a thermoformed network of yarnscomprising a first core yarn and a first polymeric composition, whereinthe first polymeric composition consolidates the thermoformed network ofyarns by surrounding at least a portion of the first core yarn andoccupying at least a portion of spaces between yarns in the thermoformednetwork of yarns, and wherein the first polymeric composition is athermoplastic elastomeric composition; optionally wherein the article isa component of an article of footwear, apparel or sporting equipment, oris an article of footwear, apparel or sporting equipment.

The present disclosure is directed to an outsole for an article offootwear, comprising:

a textile comprising a thermoformed network of yarns comprising a firstcore yarn and a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition comprises athermoplastic elastomeric polyurethane, wherein the first polymericcomposition has a Durometer Hardness of from about 70 to about 80 ShoreA, as determined using the Durometer Hardness Test;

wherein the thermoformed network of yarns is the thermoformed product ofa first textile comprising a first network of yarns including a firstcoated yarn comprising the first core yarn and a first coating, thefirst coating comprising the first polymeric composition, the first coreyarn comprising a second polymeric composition, wherein the firstcoating is axially centered surrounding the core yarn, a nominal averageouter diameter of the coated yarn is up to about 1.0 millimeter, thefirst coating has an average radial coating thickness of about 50micrometers to about 200 micrometers, and wherein, in the thermoformednetwork, the first polymeric composition consolidating the thermoformednetwork of yarns is the re-flowed and re-solidified product of the firstpolymeric composition of the first coating of the first coated yarn;

wherein, in the first coated yarn, the first thermoplastic compositionhas a first melting temperature greater than about 110 degrees Celsiusand less than about 190 degrees Celsius, the second polymericcomposition of the core yarn has a second deformation temperature, andthe second deformation temperature is at least 50 degrees Celsiusgreater than the first melting temperature of the first polymericcomposition;

wherein a first side of the thermoformed network defines at least aportion of a surface of the outsole configured to be externally-facingor ground-facing or ground-contacting when the outsole is part of afinished article of footwear.

The present disclosure is directed to an upper for an article offootwear, comprising:

a knit textile comprising a thermoformed network of interlooped yarnscomprising a first core yarn and a first polymeric composition, whereinthe first polymeric composition consolidates the thermoformed network ofinterlooped yarns by surrounding at least a portion of the first coreyarn and occupying at least a portion of spaces between yarns in thethermoformed network of yarns, wherein the first polymeric compositioncomprises a thermoplastic elastomeric polyurethane, and wherein thefirst polymeric composition has a Durometer Hardness using a Shore Ascale of from about 70 to about 80, as determined using the DurometerHardness Test;

wherein the thermoformed network of yarns is the thermoformed product ofa first textile comprising a first network of yarns including a firstcoated yarn comprising the first core yarn and a first coating, thefirst coating comprising the first polymeric composition, the first coreyarn comprising a second polymeric composition, wherein the firstcoating is axially centered surrounding the core yarn, a nominal averageouter diameter of the coated yarn is up to about 1.0 millimeter, thefirst coating has an average radial coating thickness of about 50micrometers to about 200 micrometers, and wherein, in the thermoformednetwork, the first polymeric composition consolidating the thermoformednetwork of yarns is the re-flowed and re-solidified product of the firstpolymeric composition of the first coating of the first coated yarn;

wherein, in the first coated yarn, the first thermoplastic compositionhas a first melting temperature greater than about 110 degreescentigrade and less than about 190 degrees centigrade, the secondpolymeric composition of the core yarn has a second deformationtemperature, and the second deformation temperature is at least 50degrees centigrade greater than the first melting temperature of thefirst polymeric composition;

wherein the thermoformed network of the textile defines at least aportion of a surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear;

wherein the at least a portion of the surface of the upper defined bythe thermoformed network has a total surface area of at least 1 squarecentimeter, and within the total surface area, at least 15 to 100percent of the total surface area comprises the first polymericcomposition.

The present disclosure is directed to an outsole for an article offootwear, comprising:

a textile comprising a thermoformed network of yarns comprising a firstcore yarn and a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition comprises athermoplastic elastomeric styrenic copolymer, wherein the firstpolymeric composition has a Durometer Hardness of from about 70 to about80 Shore A, as determined using the Durometer Hardness Test;

wherein the thermoformed network of yarns is the thermoformed product ofa first textile comprising a first network of yarns including a firstcoated yarn comprising the first core yarn and a first coating, thefirst coating comprising the first polymeric composition, the first coreyarn comprising a second polymeric composition, wherein the firstcoating is axially centered surrounding the core yarn, a nominal averageouter diameter of the coated yarn is up to about 1.0 millimeter, thefirst coating has an average radial coating thickness of about 50micrometers to about 200 micrometers, and wherein, in the thermoformednetwork, the first polymeric composition consolidating the thermoformednetwork of yarns is the re-flowed and re-solidified product of the firstpolymeric composition of the first coating of the first coated yarn;

wherein, in the first coated yarn, the first thermoplastic compositionhas a first melting temperature greater than about 110 degrees Celsiusand less than about 190 degrees Celsius, the second polymericcomposition of the core yarn has a second deformation temperature, andthe second deformation temperature is at least 50 degrees Celsiusgreater than the first melting temperature of the first polymericcomposition;

wherein a first side of the thermoformed network defines at least aportion of a surface of the outsole configured to be externally-facingor ground-facing or ground-contacting when the outsole is part of afinished article of footwear.

The present disclosure is directed to an upper for an article offootwear, comprising:

a knit textile comprising a thermoformed network of interlooped yarnscomprising a first core yarn and a first polymeric composition, whereinthe first polymeric composition consolidates the thermoformed network ofinterlooped yarns by surrounding at least a portion of the first coreyarn and occupying at least a portion of spaces between yarns in thethermoformed network of yarns, wherein the first polymeric compositioncomprises a thermoplastic elastomeric styrenic copolymer, and whereinthe first polymeric composition has a Durometer Hardness using a Shore Ascale of from about 70 to about 80, as determined using the DurometerHardness Test;

wherein the thermoformed network of yarns is the thermoformed product ofa first textile comprising a first network of yarns including a firstcoated yarn comprising the first core yarn and a first coating, thefirst coating comprising the first polymeric composition, the first coreyarn comprising a second polymeric composition, wherein the firstcoating is axially centered surrounding the core yarn, a nominal averageouter diameter of the coated yarn is up to about 1.0 millimeter, thefirst coating has an average radial coating thickness of about 50micrometers to about 200 micrometers, and wherein, in the thermoformednetwork, the first polymeric composition consolidating the thermoformednetwork of yarns is the re-flowed and re-solidified product of the firstpolymeric composition of the first coating of the first coated yarn;

wherein, in the first coated yarn, the first thermoplastic compositionhas a first melting temperature greater than about 110 degreescentigrade and less than about 190 degrees centigrade, the secondpolymeric composition of the core yarn has a second deformationtemperature, and the second deformation temperature is at least 50degrees centigrade greater than the first melting temperature of thefirst polymeric composition;

wherein the thermoformed network of the textile defines at least aportion of a surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear;

wherein the at least a portion of the surface of the upper defined bythe thermoformed network has a total surface area of at least 1 squarecentimeter, and within the total surface area, at least 15 to 100percent of the total surface area comprises the first polymericcomposition.

In one aspect, the deformation temperature of the polymeric compositionof the core yarn is at least 20 degrees Celsius higher than the meltingtemperature of the polymeric composition of the coating. This allows thecore yarn to be coated by the coating when the coating is in a moltenstate. In another aspect, the thermoplastic elastomer(s) of thepolymeric composition of the coating have glass transitiontemperature(s) below minus 20 degrees Celsius. This allows thethermoplastic elastomer(s) present in the polymeric composition to be intheir “rubbery” state, even when the article comprising the textile isused in cold environments. In another aspect, the melting temperature ofpolymeric composition of the coating is at least 100 degrees Celsius.This ensures the polymeric composition will not melt when the articlecomprising the textile is shipped or stored under hot conditions. Inanother aspect, the melting temperature of polymeric composition of thecoating is at least 130 degrees Celsius. This ensures the polymericcomposition will not melt when the article comprising the textile issubjected to conditions often encountered by textiles during themanufacturing processes for articles of footwear, apparel or sportingequipment, such as steaming processes. In another aspect, the meltingtemperature of polymeric composition of the coating is at less than 170degrees Celsius. This ensures the textile can be thermoformed attemperatures which do not negatively impact other textiles or componentswhich may form part of the textile or article comprising the textile.For example, dye may migrate out of package-dyed polyester yarns whenthey are exposed to temperatures greater than 150 degrees Celsius forextended periods of time. In another aspect, the enthalpy of melting ofthe thermoplastic elastomer(s) of the polymeric composition of thecoating can be less than about 30 Joules per gram or 25 Joules per gram.A lower melting enthalpy means that, during the thermoforming process,less heat and a shorter heating time is required to fully melt thepolymeric composition and achieve good flow of the molten polymericcomposition to better consolidate the network of yarns in the textile.In another aspect, the recrystallization temperature of thermoplasticelastomer(s) of the polymeric composition of the coating can be above 60degrees Celsius, or above 95 degrees Celsius. A higher recrystallizationtemperature promotes rapid re-solidification of the polymericcomposition after thermoforming, which can reduce the amount of timerequired to cool the textile after thermoforming, and may avoid the needto provide active cooling of the textile, thereby reducing cycle timeand reducing energy consumption.

The present disclosure is directed to a film, fiber, filament or yarncomprising a first polymeric composition comprising at least onethermoplastic elastomer.

The present disclosure is also directed to a textile comprising a film,fiber, filament or yarn comprising a first polymeric compositioncomprising at least one thermoplastic elastomer.

The present disclosure is also directed to process for manufacturing afilm, fiber, filament or yarn, comprising using a first polymericcomposition comprising at least one thermoplastic elastomer to form thefilm, fiber, filament or yarn.

The present disclosure is also directed to a textile comprising a firstnetwork of yarns including a first coated yarn, the first coated yarncomprising a first core yarn and a first coating including a firstpolymeric composition disposed on at least a portion of an outer surfaceof the first core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition.

The present disclosure is also directed to process for manufacturing atextile comprising using a film, fiber, filament or yarn as describedherein.

The present disclosure is also directed to an article comprising: afirst polymeric composition, wherein the first polymeric composition isa reflowed and re-solidified product of a film, fiber, filament or yarnas described herein; and a second element selected from a second shapedcomponent, a second film, a second fiber, a second filament, a secondyarn, or a second textile.

The present disclosure is also directed to a process for manufacturingan article, the process comprising: placing a first film, fiber,filament, yarn, or textile comprising a first polymeric compositioncomprising a thermoplastic elastomer as described herein, or a textilecomprising the first polymeric composition comprising the thermoplasticelastomer as described herein on a surface; while the first film, fiber,filament, yarn or textile is on the surface, increasing a temperature ofthe first film, fiber, filament, yarn or textile to a temperature thatis above the melting temperature of the first polymeric composition; andsubsequent to the increasing the temperature, while the first film,fiber, filament, yarn or textile remains on the surface, decreasing thetemperature to a temperature below the melting temperature of the firstpolymeric composition, thereby forming a article.

Described herein are films comprising a first polymeric compositioncomprising at least one thermoplastic elastomer. In some aspects, thefirst polymeric composition of the film can be a low processingtemperature polymeric composition. In various aspects, the film can be amulti-layered film comprising a first layer comprising the firstthermoplastic elastomer. For example, the multi-layered film can be abilayer film comprising a first layer comprising the first thermoplasticelastomer and a second layer comprising a second polymeric material. Thesecond polymeric material can be a second thermoplastic compositioncomprising a second thermoplastic elastomer. The multi-layered film canbe formed by co-extrusion or lamination.

Described herein are fibers comprising the first polymeric compositioncomprising at least one thermoplastic elastomer. As used herein, the“fiber” is understood to be a fiber suitable for use in a yarn or atextile. A fiber has a small diameter relative to its length, where itslength is discrete, e.g., a cut or staple fiber include filaments. Invarious aspects, the fiber can be a single-component fiber composed ofone thermoplastic composition. In other aspects, the fiber can be abi-component fiber composed of two thermoplastic compositions. In afurther aspect, the fiber can be a multi-component fiber composed ofthree or more thermoplastic compositions.

Described herein are filaments comprising the first polymericcomposition comprising at least one thermoplastic elastomer. As usedherein, the “filament” is understood to be filament suitable for use ina yarn or a textile. A filament has a small diameter relative to itslength, where its length is many orders of magnitude greater than itsdiameter, such as a silk filament or extruded filament, or can besubstantially continuous, such as an extruded filament. In variousaspects, the filament can be a single-component filament composed of onethermoplastic composition. In other aspects, the filament can be abi-component filament composed of two thermoplastic compositions. In afurther aspect, the filament can be a multi-component fiber composed ofthree or more thermoplastic compositions. The filament can be a singlefilament, e.g., a monofilament. Alternatively, the filament can be aplurality of filaments. The plurality of filaments can include filamentsformed of a single thermoplastic composition, or a plurality offilaments formed from two or more different thermoplastic compositions.The plurality of filaments can be a plurality of loose (i.e., notentangled) filaments, or can be a plurality of entangled filaments.

Described herein are yarns useful in making textiles. In one aspect, theyarn comprises a coating of a first polymeric composition comprising atleast one thermoplastic elastomer. The yarns can be formed using staplefibers or continuous filaments comprising of the thermoplasticcomposition. In one aspect, the fibers or filaments used to produce theyarn comprise a single polymeric composition. The first polymericcomposition can be a low processing temperature polymeric composition.In one example, the yarn can be a coated yarn having a core, wherein thecore comprises a high processing temperature polymeric composition, andthe coating comprises the low processing temperature polymericcomposition. Alternatively, the yarn can comprise fibers, filaments,cores and/or coatings formed from two or more different polymericcompositions.

In one aspect, using a coated yarn allows the incorporation of desirablerubbery polymeric properties into textiles. In one aspect, tensilestrength of a 150 denier, high tenacity core polyester eliminates excessstretch and heat shrink risks. In one aspect, the tensile strength ofthe yarn is about 1 kilogram-·force at break, and less than 20 percentstrain to break, or less than 15 percent strain to break, or from about10 to about 12 percent strain to break. In another aspect, heat shrinkfor the coated yarns is less than 20 percent or less than 10 percentupon heating.

In some aspects, use of lubricating oil such as mineral oil or siliconeoil enables knitting of elastomer-coated yarns to be comparable toknitting of common polyester yarns. In one aspect, from about 0.1 weightpercent to about 3 weight percent of the textile, or about 0.5 weightpercent to about 2 weight percent of the textile. In one aspect, thelubricating composition can be applied to the coated yarn after thecoating process. In another aspect, the lubricating compositions can beadmixed with the first polymeric composition prior to coating the coreyarn.

In another aspect, the yarn can be coated by any method known in theart. In one aspect, the polymeric coating compositions disclosed hereinare suitable for manufacturing by pultrusion and/or pulling the yarnsthrough baths of liquid polymeric materials. In still another aspect,regardless of coating process, sufficient coating material is providedon the yarn such that, when knit or woven alone or with one or moreother yarns in various configurations and subsequently thermoformed andallowed to re-flow and re-solidify, the polymeric material forms astructure with an adequate concentration of the polymeric material onone or more surfaces, and/or within the core, depending upon theplacement of the coated yarn within the knit or woven structure.

The foregoing films, fibers, filaments, yarns, or any combinationthereof, can be used to prepare a textile. The textile can comprise oneor more of the disclosed films, fibers, filaments or yarns. In variousaspects, the textile can be a woven textile comprising one or more ofthe disclosed films, fibers, filaments, or yarns. In a further aspect,the textile can be a knit textile comprising one or more disclosedfilms, fibers, filaments, or yarns. In a still further aspect, thetextile can be a non-woven textile comprising one or more of thedisclosed films, fibers, filaments or yarns. In other aspects, thetextile can be a crocheted textile or braided textile comprising one ormore of the disclosed films, fibers, filaments or yarns.

In an aspect, a textile is provided comprising a first film, fiber,filament or yarn described herein. In one aspect, the textile furtherincludes a second yarn, where the second yarn is different from thefirst yarn (e.g., comprises at least one thermoplastic elastomer thatdiffers from a thermoplastic elastomer of the first polymericcomposition based on molecular weight, polymeric structure, meltingtemperature, melt flow index, hardness, or modulus). In another aspect,the second yarn is substantially free of a thermoplastic elastomer.

In one aspect, the textile comprises a first network of yarns includinga first coated yarn, where the first coated yarn includes a first coreyarn and a first coating including a first polymeric compositiondisposed on at least a portion of an outer surface of the first coreyarn, wherein the first polymeric composition is a thermoplasticelastomeric composition.

The first yarn and second yarn can be used so as to form separate zonesof the textile. For example, the first yarn can form a majority of afirst surface of the textile, and the second yarn can form a majority ofa second surface opposing the first surface of the textile. The firstyarn and the second yarn can be laid down in a first zone and anadjacent second zone, wherein the first zone comprises an increasedconcentration of the second yarn compared to the second zone. The firstyarn and the second yarn can be laid down in a first zone, a secondzone, and a third zone, the second zone positioned between the first andthird zones, wherein the first zone comprises an increased concentrationof the second yarn compared to the second zone, and wherein the thirdzone comprises an increased concentration of the first yarn compared tothe second zone. percent

In an aspect, a woven textile is provided comprising a first film,fiber, filament, or yarn as described herein. Optionally, the woventextile further includes a second film, fiber, filament or yarn, wherethe second yarn has a higher melting or deformation temperature from thefirst yarn. In another aspect, the second film, fiber, filament or yarnis substantially free of a thermoplastic elastomer. The first film,fiber, filament or yarn and the second film, fiber, filament or yarn canbe used to form separate zones of the woven thermoformed textile. Forexample, a first yarn can form substantially all or a portion of a warpof the weave of the woven thermoformed textile, and a second yarn canform substantially all or a portion of a weft of the weave of the woventhermoformed textile, or vice versa.

In an aspect, a knit or crochet textile is provided comprising a firstfilm, fiber, filament or yarn as described herein. The knit or crochettextile can optionally further include a second film, fiber, filament oryarn, where the second film, fiber, filament or yarn has a highermelting temperature or deformation temperature from the first film,fiber, filament or yarn In another aspect, the second film, fiber,filament or yarn is substantially free of a thermoplastic elastomer. Afirst yarn and a second yarn can at least partly form a plurality ofinterconnected courses in at least one knit layer of a knit textile.Alternatively, the knit or crochet textile can include interconnectedloops comprising a second yarn and inlaid portions comprising the firstfilm, fiber, filament or yarn, wherein the second yarn has a meltingtemperature or deformation temperature greater than the meltingtemperature of the first polymeric composition.

The knit textile can be formed through one or more of a variety of aknitting process, such as flat knitting or circular knitting. Forexample, a flat knitting process can be utilized to manufacture the knittextile. Although flat knitting can provide a suitable process forforming the knit textile, other knitting processes can also be utilizedsuch as wide tube circular knitting, narrow tube circular knit jacquard,single knit circular knit jacquard, double knit circular knit jacquard,warp knit tricot, warp knit raschel, and double needle bar raschel. Inaspects, the knit textile can be subject to post-processing steps, e.g.,to remove a portion of the knit textile, to add components to the knittextile, to create a fleece texture, etc. In other aspects, the knittextile can comprise various knitted structures and/or comprisedifferent knitted sublayers.

In certain aspects, the knit textile can be a knit article having asubstantially seamless configuration. In certain aspects, the entireknit article can be seamless. The seamless knit article may, forexample, be provided by circular knitting. A circular knit article canallow a three-dimensionally preshaped article to be provided withouthaving to be sewn up at a designated place(s). Thus, unwanted seams inthe knit article can be avoided and the three-dimensionally preshapedknit article can have a particularly good fit and the additionalaforementioned benefits of a seamless structure.

In a further aspect, the knit textile can be a knit article formed ofunitary knit construction. As utilized herein, a knit article is definedas being formed of “unitary knit construction” when formed as aone-piece element through a knitting process. That is, the knittingprocess substantially forms the various features and structures of theknit article without the need for significant additional manufacturingsteps or processes. Although portions of the knit article can be joinedto each other (e.g., edges of the knit article being joined together, asat seam) following the knitting process, the knit article remains formedof unitary knit construction because it is formed as a one-piece knitelement. In various aspects, the knit article can further comprise otherelements (e.g., a tongue, a strobel, a lace, a heel counter, logos,trademarks, placards) that can be added following the knitting process.

The knit textile can incorporate various types and combinations ofstitches and yarns. With regard to stitches, the knit textile can haveone type of stitch in one area of the knit textile and another type ofstitch in another area of the knit textile. Depending upon the types andcombinations of stitches utilized, areas of the knit textile can have,for example, a plain knit structure, a mesh knit structure, or a ribknit structure. The different types of stitches may affect the physicalproperties of the knit textile, including aesthetics, stretch,thickness, air permeability, and abrasion-resistance. That is, thedifferent types of stitches may impart different properties to differentareas of knit textile. With regard to yarns, the knit textile may haveone type of yarn in one area of the knit textile and another type ofyarn in another area of the knit textile, e.g., a yarn comprising afirst polymeric composition in one area of the knit textile and a yarncomprising a second polymeric composition, such as a thermoplasticcomposition, in another area of the knit textile. Depending upon variousdesign criteria, the knit textile can incorporate yarns with differentdeniers, materials (e.g., cotton, elastane, polyester, rayon, wool, andnylon), and degrees of twist, for example. The different types of yarnsmay affect the physical properties of the knit textile, includingaesthetics, stretch, thickness, air permeability, andabrasion-resistance. That is, the different types of yarns may impartdifferent properties to different areas of the knit textile. Bycombining various types and combinations of stitches and yarns, eacharea knit article can have specific properties that enhance the comfort,durability, and performance of the knit textile as required by its usein an article of footwear, article of apparel, or article of sportingequipment.

It should be noted, however, that the textiles and thermoformed textilesof the present disclosure, including knit articles, can be utilized inmanufacture of composite elements. In some aspects, a composite elementcan comprise a first textile prepared as disclosed herein, along with asecond textile or a film or a shaped component. That is, the compositeelement comprises a first textile region and a second region selectedfrom a region comprising a second textile, a region comprising a film, aregion comprising a shaped component, or combinations thereof.

In certain aspects, a thermoformed textile is provided according to thepresent disclosure. As used herein, a thermoformed textile is understoodto be a textile comprising the first polymeric composition that has beenthermoformed to have a different shape or texture or both. Thethermoforming can be conducted on a substantially flat surface such as aplate, or in a shaped mold, or on a shaped article such as a last. Forexample, the thermoformed textile is a textile in which at least aportion of the first polymeric composition present in the textile hasbeen thermoformed (i.e., softened, molded and re-solidified, or melted,molded and re-solidified, such that at least a portion of the firstnetwork of yarns of the textile becomes a thermoformed network of yarnsin which the first polymeric composition of the coated yarn consolidatesthe thermoformed network of yarns by surrounding at least a portion ofthe first core yarn and occupying at least a portion of spaces betweenyarns). Once thermoformed, the first polymeric composition of athermoformed textile has a different physical shape than before it wasthermoformed and retains this second shape until the first polymericcomposition is thermoformed again. In one example, the thermoformingprocess re-flows the first polymeric composition from a first state as afirst film to a second state in which the first polymeric compositionpenetrates into or between portions of the textile which had surroundedthe first film. For example, during the thermoforming process, themolten first polymeric composition may penetrate between or into secondfibers, filaments or yarns of the textile, and may, when re-solidified,act as a consolidating resin for the second fibers, filaments or yarns.In another example, the thermoforming process re-flows the plurality offibers, filament, plurality of filaments, yarn, plurality of yarns, orany combination thereof, into a second state, in which the firstpolymeric composition no longer has a fibrous, filamentous, or yarn-likeconfiguration.

The thermoformed textile comprising the first polymeric composition canbe a thermoformed textile wherein at least a portion of the film,plurality of fibers, filament, plurality of filaments, yarn, yarns, orany combination thereof have been at least partially melted andre-solidified into a new conformation which is different than theiroriginal (i.e., pre-thermoforming) conformation. The thermoformedtextile can comprise a partially re-flowed structure in which only aportion of the first polymeric composition present in the textile hasbeen re-flowed, or an essentially completely re-flowed structure inwhich substantially all of the first polymeric composition present inthe textile has been re-flowed. The thermoformed textile can alsoinclude a second plurality of fibers including a second polymericcomposition, such as a second polymeric composition comprising a secondthermoplastic elastomer. In an aspect, zones or regions of the textilecan be thermoformed into continuous, film-like layers, or thermoformedand molded to adopt desired surface topographies.

The textile or thermoformed textile as described herein can be acomponent of an article of footwear. The textile or thermoformed textilecan be used to provide or enhance properties of the article such as, forexample, abrasion resistance, traction, grip, or a combination of theseproperties to at least a portion of the article of footwear. Thetextiles described herein can define an externally-facing surface of thearticle of footwear. In one aspect, the textile or thermoformed textileis a component of an upper for an article of footwear. In one aspect,disclosed herein is an upper for an article of footwear comprising atextile, wherein the textile comprises a first network of yarnsincluding a first coated yarn, where the first coated yarn comprises afirst core yarn and a first coating including a first polymericcomposition disposed on at least a portion of an outer surface of thefirst core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition. In an aspect, the textile definesat least a portion of a surface of the upper configured to be externallyfacing when the upper is part of a finished article of footwear.

In another aspect, the textile or thermoformed textile is an outsole foran article of footwear or is a component of an article of footwear. Inanother aspect, the textile or thermoformed textile is a rand or zonebridging a region between a footwear upper and the sole structure. Inyet another aspect, the textile or thermoformed textile is a combinationupper and outsole for an article of footwear, wherein the upper includesan integrated outsole area. Optionally, the upper and the integratedoutsole area are at least partially formed from a textile. The outsole,or the outsole area of the combination upper and outsole can beconfigured to include a ground-facing surface, or a ground-contactingsurface, or both, and at least a portion of the textile described hereindefines at least a portion of the ground-facing surface, or theground-contacting surface, or both. For example, the outsole or outsolearea can be configured to include a ground-facing surface but not aground-contacting surface, and at least a portion of the textile definesat least a portion of the ground-facing surface. In another example, theoutsole or outsole area can be configured to include a ground-facingsurface but not a ground-contacting surface, and at least a portion ofthe textile defines at least a portion of the ground-facing surface, andwherein the at least a portion of the textile defines the at least aportion of the ground-facing surface is textured, or includes at leastone traction element, or both. Optionally, the at least one tractionelement can a thermoformed traction element formed from the textile.

The textile or thermoformed textile as described herein can be acomponent of an article of apparel. The textile can define anexternally-facing surface of the article of apparel. The textile orthermoformed textile can be used to provide abrasion resistance ortraction or both to at least a portion of the article of apparel, suchas, for example on an elbow area, a knee area, or both. The textile orthermoformed textile can be used to provide protection to electroniccomponents embedded in or attached to the article of apparel. Thetextile or thermoformed textile can be used to provide protection to awearer from hard or sharp components embedded in or attached to thearticle of apparel.

The textile or thermoformed textile as described herein can be acomponent of an article of sporting equipment. The textile can define anexternally-facing surface of the article of sporting equipment. Thetextile or thermoformed textile can be used to provide abrasionresistance or traction or both to at least a portion of the article ofsporting equipment, such as a portion of the article of sportingequipment which contacts the ground or had surfaces during use. Thetextile or thermoformed textile can be used to provide protection toelectronic components embedded in or attached to the article of sportingequipment.

In certain aspects, the present disclosure is also directed to articlescomprising a thermoformed film component that has been thermoformed froma first state as a film into a second state as a softened or melted andre-solidified film (i.e., a film comprising a first polymericcomposition, wherein at least a portion of the film has been softened ormelted and re-solidified into a new conformation which is different thanits original film conformation prior to thermoforming). Thethermoforming can be conducted on a substantially flat surface such as aplate, or in a shaped mold, or on a shaped article such as a last.

The thermoformed film component as described herein can be a componentof an article of footwear. The thermoformed film component can be usedto provide abrasion resistance or traction or both to at least a portionof the article of footwear. The first polymeric composition can definean externally-facing surface of the article of footwear. In one aspect,the thermoformed film component is a component of an upper for anarticle of footwear. In another aspect, disclosed herein is an upper foran article of footwear comprising a textile comprising a thermoformednetwork of yarns comprising a first core yarn and a first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns, and wherein the first polymericcomposition is a thermoplastic elastomeric composition. In an aspect thetextile can define at least a portion of a surface on the upperconfigure to be externally-facing when the upper is part of a finishedarticle of footwear. In another aspect, the first polymeric compositioncan define at least a portion of the surface of the upper configured tobe externally-facing when the upper is part of a finished article offootwear, or defines at least a portion of a surface of the upperconfigured to be internally-facing when the upper is part of a finishedarticle of footwear, or forms at least a portion of an interior layer ofthe upper when the upper is part of a finished article of footwear, orany combination thereof.

In another aspect, the thermoformed film component is an outsole for anarticle of footwear or is a component of an article of footwear. In yetanother aspect, the thermoformed film component is a combination upperand outsole for an article of footwear, wherein the upper includes anoutsole area. The outsole, or the outsole area of the combination upperand outsole can be configured to include a ground-facing surface, or aground-contacting surface, or both, and at least a portion of the firstpolymeric composition defines at least a portion of the ground-facingsurface, or the ground-contacting surface, or both. For example, theoutsole or outsole area can be configured to include a ground-facingsurface but not a ground-contacting surface, and at least a portion ofthe first polymeric composition defines at least a portion of theground-facing surface. In another example, the outsole or outsole areacan be configured to include a ground-facing surface but not aground-contacting surface, and at least a portion of the first polymericcomposition defines at least a portion of the ground-facing surface, andwherein the at least a portion of the first polymeric compositiondefines the at least a portion of the ground-facing surface is textured,or includes at least one traction element, or both. Optionally, the atleast one traction element can a thermoformed traction element formedfrom the textile.

The thermoformed film component as described herein can be a componentof an article of apparel. The first polymeric composition can define anexternally-facing surface of the article of apparel. The thermoformedfilm component can be used to provide abrasion resistance or traction orboth to at least a portion of the article of apparel, such as, forexample on an elbow area, a knee area, or both. The thermoformed filmcomponent can be used to provide protection to electronic componentsembedded in or attached to the article of apparel. The thermoformed filmcomponent can be used to provide protection to a wearer from hard orsharp components embedded in or attached to the article of apparel.

The thermoformed film component as described herein can be a componentof an article of sporting equipment. The first polymeric composition candefine an externally-facing surface of the article of sportingequipment. The thermoformed film component can be used to provideabrasion resistance or traction or both to at least a portion of thearticle of sporting equipment, such as a portion of the article ofsporting equipment which contacts the ground or had surfaces during use.The thermoformed film component can be used to provide protection toelectronic components embedded in or attached to the article of sportingequipment.

The present disclosure is also directed to articles comprising: atextile comprising a thermoformed network of yarns comprising a firstcore yarn and a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition; and a second element selected from a secondshaped component, a second film, a second fiber, a second filament, asecond yarn, or a second textile. The article can be a textile orthermoformed textile as described herein, wherein the article includesthe re-flowed and re-solidified product of the first polymericcomposition, and the second element selected from the second shapedcomponent, second film, second fiber, second filament, second yarn, orsecond textile. The article can be a thermoformed film component asdescribed herein, wherein the article includes the re-flowed andre-solidified product of the first polymeric composition, and the secondelement selected from the second shaped component, second film, secondfiber, second filament, second yarn, or second textile.

In some aspects, the article is an article of footwear, which includes,but is not limited to, such articles as shoes. “Article of footwear” isused to refer to an article intended for wear on a human foot, e.g., insome aspects, an article of footwear can be a shoe, such as an athleticshoe. Articles of footwear generally include an upper and a solestructure. The upper provides a covering for the foot that comfortablyreceives and securely positions the foot with respect to the solestructure. Moreover, the upper generally provides protection for thefoot and may provide other attributes such as weather resistance, waterresistance, contact or interaction with athletic equipment, or the like.The sole structure can provide various kinds of support, cushioning andshock absorption. The sole structure is secured to a lower portion ofthe upper and is generally positioned between the foot and the ground.In addition to attenuating ground reaction forces (that is, providingcushioning) during walking, running, and other ambulatory activities,the sole structure can influence foot motions (for example, by resistingpronation), impart stability, and provide traction, for example.Accordingly, the upper and the sole structure operate cooperatively toprovide a comfortable structure that is suited for a wide variety ofactivities.

An exemplary article of footwear is athletic or sports footwear,including, but not limited to, running shoes, basketball shoes, soccershoes, baseball shoes, football shoes, tennis shoes, rugby shoes,cross-training shoes, walking shoes, hiking boots, golf shoes, sneakers,and the like. Alternatively, the article of footwear can be non-athleticfootwear, including, but not limited to, dress shoes, loafers, casualwear shoes, sandals, and boots, including work boots. A shoe can orcannot enclose the entire foot of a wearer. For example, a shoe could bea sandal or other article that exposes large portions of a wearing foot.The person of ordinary skill in the art can appreciate, therefore, thatthe materials and processes disclosed herein apply to a wide variety offootwear types or styles, in addition to the specific type or stylediscussed in the following material and depicted in the accompanyingfigures.

An upper forms a structure that that provides a covering for some or allof a wearer's foot and positions that foot relative to a sole structureof that shoe. The upper forms a void on the interior of the footwear forreceiving the foot. The void has the general shape of the foot, andaccess to the void can be provided at an ankle opening. In certainaspects, the upper extends over the instep and toe areas of the foot,along medial and lateral sides of the foot, and around the heel area ofthe foot. The upper can have any design, shape, size and/or color. Forexample, in certain aspects, e.g., if an article is a basketball shoe,then the upper can be a high top upper that is shaped to provide highsupport on an ankle. Alternatively, in certain aspects, e.g., if anarticle is a running shoe, then the upper can be a low top upper. Inaccordance with the present disclosure, the upper or upper component cancomprise a film, fiber, filament, yarn, textile, thermoformed textile,or thermoformed film component as described herein.

The upper can also incorporate a closure system such as a lacing systemto permit entry and removal of the foot from the void within the upper.Additionally or alternatively, the upper can also incorporate anadjustment system to adjust fit of the footwear and/or provide lock-downbetween the upper and the sole structure. A closure and/or adjustmentsystem such as a lacing system often is incorporated into the upper toselectively change the size of the ankle opening and to permit thewearer to modify certain dimensions of the upper, particularly girth, toaccommodate feet with varying proportions. In addition, the upper caninclude a tongue that extends under the lacing system to enhance thecomfort of the footwear (e.g., to modulate pressure applied to the footby the laces). The tongue can be attached at the base of the lacingstructure; can be attached at the base of the lacing structure and onthe medial side of the lacing structure, or on the lateral side of thelacing structure, or on both sides; or can be integrally formed with theupper. The upper can include a heel counter to limit or control movementof the heel. The upper can include a toe cap to provide abrasionresistance or protection or both to the toe box portion of the upper.Abrasion resistance, traction, or both can be provided in specificregions of the upper including on portions of the medial side, thelateral side, the instep region, or any combination thereof. Forexample, use of materials which provide increased levels of traction areuseful on athletic footwear which may come into contact with a ballduring use. Optionally, the upper can include a heel counter; a toe cap;an abrasion resistant region on the medial side, the lateral side, orthe instep; a region of increased traction on the medial side, thelateral side, or the instep; or any combination thereof.

In one aspect, a textile, including a thermoformed textile, as describedherein defines at least a portion of an outer surface of the upper. Inanother aspect, the textile as described herein defines at least aportion of the surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear, or defines atleast a portion of a surface of the upper configured to beinternally-facing when the upper is part of a finished article offootwear, or forms at least a portion of an interior layer of the upperwhen the upper is part of a finished article of footwear, or anycombination thereof.

In one aspect, the textiles, including the thermoformed textilesdescribed herein can cover from about 15 percent to about 100 percent ofthe outward-facing surface area of an upper. In one aspect, the textilecovers from about 15 percent to about 35 percent of the surface area ofthe external face of the upper. In another aspect, the textile coversfrom about 40 percent to about 70 percent of the surface area of theexternal face of the upper. In another aspect, the textile covers fromabout 75 percent to about 100 percent of the surface area of theexternal face of the upper.

In another aspect, the textiles, including the thermoformed textiles,can be present on a lateral side of the upper, a medial side of theupper, a heel region of the upper, a toe region of the upper, or anycombination thereof. In some aspects, when the textiles form part or allof an upper for an article of footwear, the textiles can be present in afirst layer and a second layer. In one aspect, the first layer can be anoutward facing layer and the second layer can be a base layer orinternal layer that is not seen when the article of footwear is beingworn. In another aspect, the first layer and second layer canindependently comprise a knitted textile, a crocheted textile, a braidedtextile, a woven textile, a non-woven textile, or some combinationthereof. In one aspect, when two layers of the textiles are present, thetop layer can be useful for boot-to-ball control, abrasion resistance,and stretch resistance and the bottom layer can be useful for providingwater resistance, stretch resistance, and durability to the article offootwear. In some aspects, a core layer can be present between the toplayer and the base layer. In an alternative aspect, the textile can bepresent as a single layer comprising an outward-facing side, aninward-facing side, and a core, wherein the outward-facing sidecomprises the coated yarns which can be useful for boot-to-ball control,abrasion resistance, and stretch resistance, and the inward-facing sidecomprises the coated yarns which can be useful for water resistance,stretch resistance, and durability, among other properties.

In some aspects, a sole structure can include one or more components orlayers, which can individually or collectively provide an article offootwear with a number of attributes, such as support, rigidity,flexibility, stability, cushioning, comfort, reduced weight, or otherattributes. In some aspects, a sole structure can comprise layersreferred to as an insole, a midsole, and an outsole. In some aspects,however, one or more of these components can be omitted. In certainaspects, a sole structure can optionally comprise a sole plate. In someaspects, the sole structure comprises at an outsole component thatincludes an exterior major surface, which can be exposed andground-contacting, and an interior major surface. In a further aspect,the sole structure can further comprise a midsole component that can beattached to the upper along the entire length of the upper. Whenpresent, the midsole forms the middle layer of the sole structure andserves a variety of purposes that include controlling foot motions andattenuating impact forces.

The outsole includes the ground-contacting portions of the article offootwear. Conventionally, durable, wear-resistant materials are used foroutsoles. In accordance with the present disclosure, the outsole oroutsole component can comprise a film, fiber, filament, yarn, textile,thermoformed textile, or thermoformed film component as describedherein. Outsoles commonly include texturing or other features such astraction elements to improve traction. The outsole can optionallyfurther comprise one or more integrally formed or removable cleats.

In one aspect, the textile defines at least a portion of anexternally-facing surface of the outsole, optionally wherein theexternally-facing surface is configured to be ground-facing orground-contacting when the outsole is part of a finished article offootwear. In another aspect, the textile defines at least a portion ofthe medial side or lateral side of the outsole.

A combination upper and outsole for an article of footwear is anintegrated component which serves both as the upper of the article offootwear and as the outsole of the article of footwear. In contrast toconventional footwear formed by first forming a separate upper and aseparate outsole, and then attaching the upper and the outsole to eachother. In contrast, in a combination upper and outsole, at least aportion of the upper area and the outsole area of the unit are formed atthe same time, for example, by thermoforming one or more components on alast. Thus, the combination upper and outsole unit comprises a singletextile, thermoformed textile, or thermoformed film component whichforms both at least a portion of the externally-facing surface of theupper and at least a portion of the ground-facing or ground-contactingsurface of the outsole.

Exemplary Aspects of Articles of Sporting Equipment, Articles of Wearand Textiles

As discussed above, certain aspects are directed to one or moretextiles, thermoformed textiles, or thermoformed film components thatinclude the films, fibers, filaments or yarns as described herein. Incertain aspects, such textiles, thermoformed textiles, or thermoformedfilm components can form at least a portion of an article of sportingequipment or article of wear, including articles of apparel and articlesof footwear. In certain aspects, the disclosed textiles, thermoformedtextiles, or thermoformed film components can form at least a portion ofa component of an article of footwear. In certain aspects, the disclosedtextiles, thermoformed textiles, or thermoformed film components canform at least a portion of a component of an article of sportingequipment.

Turning now to the figures, in particular, FIGS. 1A and 1B, an articleof footwear 100 is depicted as one exemplary article of wear. WhileFIGS. 1A and 1B depict an article of footwear 100, it should beunderstood that other articles of wear are also contemplated by thepresent disclosure. The article of footwear 100 of FIGS. 1A and 1Bgenerally can include a ground-facing outsole area 110, an ankle collararea 112, a lateral midfoot area 114 a, and a medial midfoot area 114 b,a toe box area 116, and a heel area 118. Further, the article offootwear 100 can include a plurality of eyestays 120, a vamp area 122, atongue area 124, and a throat area 126. As shown in FIGS. 1A and 1B,article of footwear 100, is intended to be used with a right foot;however, it should be understood that the following discussion canequally apply to a mirror image of article of footwear 100 that isintended for use with a left foot.

The article of footwear 100 depicted in FIGS. 1A and 1B can include atleast one textile 102 that at least partly forms a portion of thearticle of footwear 100. Optionally, the textile 102 of the article offootwear 100 can include at least two, or optionally at least threeseparate textile zones, e.g., zones 104, 106, and 108, identifyingspecific functional areas of the article of footwear 100. In certainaspects, these specific functional areas are at least partly associatedwith the targeted incorporation of specific textile media in varyingamounts, techniques, and combinations into these textile zones(illustrated as zones 104, 106, and 108 in FIGS. 1A and 1B). It shouldbe understood that, while the textile 102 includes three specificfunctional areas, more than three functional areas are alsocontemplated.

In certain aspects, the textile zone 104 can exhibit a rigid orsemi-rigid functionality suitable for use as a ground-facing outsole 110for the article of footwear 100. Accordingly, in certain aspects, thetextile zone 104 can be positioned to include at least a portion of aground-facing outsole 110 of the article of footwear 100. In certainaspects, the targeted incorporation of the films, fibers, filaments oryarns described herein into the textile zone 104 of the textile 102,upon thermoforming, can at least partly provide the abrasion-resistantand/or traction functionality for use as a ground-facing outsole 110.

Further, in aspects, another textile zone, such as, for example, textilezone 108, can exhibit flexibility and/or pliability to accommodatemovements from a wearer. In certain aspects, the textile zone 108 caninclude the ankle collar area 112, the tongue area 124, and/or thethroat area 126 of the article of footwear 100.

In certain aspects, another textile, such as, for example, zone 106, canbe positioned between the textile zones 104 and 108. In certain aspects,the textile zone 106 can include at least a portion of the lateralmidfoot region 114 a and/or the medial midfoot region 114 b on thearticle of footwear 100. In certain aspects, the textile zone 106 caninclude a combination of a first film, fiber, filament or yarn describedherein from the textile zone 104 with a second film, fiber, filament oryarn, such as, for example, the second film, fiber, filament or yarnfrom the textile zone 108, where the second film, fiber, filament oryarn has different properties (e.g., melting temperature, deformationtemperature, etc.) compared to the first film, fiber, filament or yarn.In such aspects, this combination of textile media present in thetextile zone 106 allows the textile zone 106 to function as a flexible,pliable portion of the upper and as an abrasion-resistant or hightraction zone, and optionally as a transition between the outsolefunctionality of the textile zone 104 and the flexible pliablefunctionality of the textile zone 108, allowing for a more gradualtransition from the outsole portion to flexibility of the textile 102.In one example, only textile zone 104 comprises the first polymericcomposition of the disclosure. In another example, only textile zone 106comprises the first polymeric composition of the present disclosure. Inanother example, both textile zones 104 and 106 comprise the firstpolymeric composition, wherein a concentration of the first polymericcomposition in textile zone 104 is greater (e.g., at least 10 weightpercent greater, at least 20 weight percent greater, or at least 30weight percent greater) than in textile zone 106. In yet anotherexample, textile zone 108 is substantially free of the first polymericcomposition of the disclosure.

Further, in such aspects, the textile zone 106 can exhibit rigidity orsemi-rigidity to a lesser extent than the textile zone 104, but to agreater extent than the textile zone 108. Also, in the same oralternative aspects, the textile zone 106 can exhibit flexibility to alesser extent than the textile zone 108, but to a greater extent thanthe textile zone 104.

Alternatively or additionally, the three textile zones 104, 106 and 108can be at least partly located within a midfoot region, such as lateralmidfoot region 114 a and/or medial midfoot region 114 b.

While any or all of textile zones 104, 106 and 108 can be formed ofseparate textiles operably connected to each other, a single textilehaving two or more integrally formed textile zones can be used. In oneparticular example, a single upper and outsole unit comprises two ormore separately formed or integral textile zones.

In certain aspects in the textile zone 106, the combination of the firstfilm, fiber, filament or yarn described herein is present in the textilezone 104 and a second film, fiber, filament or yarn described herein ispresent in the textile zone 108. When this textile is exposed to thethermoforming process, the process can impart one or more structuralproperties to these zones making them appropriate for use in the articleof footwear 100, such as abrasion resistance, improved traction,semi-rigid support, or any combination thereof, in the lateral and/ormedial midfoot regions 114 a and 114 b, and/or three-dimensional shapeor structure suitable for one or more portions of the article offootwear 100.

In certain aspects, as can be seen in FIG. 1A, the textile zone 106extends away from the textile zone 104 towards the eyestays 120. In suchaspects, the combination of textile media comprising the first film,fiber, filament or yarn described herein and textile media comprisingthe second film, fiber, filament or yarn can allow for the transferringof a force transmitted from the eyestays 120 or other lacing mechanismsinto this combination of textile media present in the lateral and/ormedial midfoot regions 114 a and 114 b. In certain aspects, for thesuccessful transfer of the forces transmitted from the eyestays 120, thetextile zone 104, and/or the first film, fiber, filament or yarndescribed herein present in the textile zone 104, can terminate to anarea 128 that is a distance of at least about 0.5 cm, about 1.0 cm, orabout 2.0 cm from the eyestays 120, and/or at least about 3, at leastabout 4, or at least about 5 needle lengths below the eyestays 120, whenthe textile 102 is a knit textile formed on a commercial knittingmachine. In such aspects, the flexible and pliable characteristics ofthe second film, fiber, filament or yarn that are present in the zone108 that is adjacent the eyestays 120 can facilitate in transferringforces transmitted from the eyestays 120 to the textile zone 106 and/orthe first films, fibers, filaments or yarns described herein present inthe lateral and/or medial midfoot regions 114 a and 114 b.

In the aspect depicted in FIGS. 1A and 1B, the textile zone 106 ispositioned in the toe box area 116 and the heel area 118. In suchaspects, the combination of the first film, fiber, filament or yarndescribed herein and the second film, fiber, filament or yarn canprovide structure and/or support due to the rigidity provided by thethermoformed material. Further, the thermoformed material can provideabrasion resistance or increased traction in the toe box area 116 and/orthe heel area 118. In alternative aspects, the textile zone 104 can format least a portion of the toe box area 116 and/or the heel area 118 forincreased rigidity or increased abrasion resistance or traction, sincethe textile zone 104 includes a greater amount, or alternativepositioning (e.g., outer knit surface), of the first film, fiber,filament or yarn described herein than the textile zone 106.

FIG. 1C depicts an alternative aspect of an article of footwear 100 a.In such aspects, the article of footwear 100 a can generally include atleast three types of textile zones: the textile zone 104 a, the textilezone 106 a, and the textile zone 108 a. In certain aspects, the textilezones 104 a, 106 a, and 108 a can have the same properties andparameters as the textile zones 104, 106, and 108, respectively, of thearticle of footwear 100 discussed above with reference to FIG. 1A.

In the aspect depicted in FIG. 1C, portions, e.g., portions 104 b and104 c, of the textile zone 104 a can extend from an outsole area upthrough a midfoot area 115A and toward a plurality of eyestays 120 a. Insuch aspects, a rigid or semi-rigid functionality provided by theportions 104 b and 104 c extending from an outsole area through themidfoot area 115A to a plurality of eyestays 120 a can provide increasedwearer stability in the midfoot area 115A. Further, in aspects, a forceapplied through one or more of the plurality of eyestays 120 a can atleast partly be transferred onto the rigid or semi-rigid portions 104 band 104 c extending through the midfoot area 115A, and into the rigid orsemi-rigid textile zone 104 a present in an outsole area, providingincreased support and comfort for a wearer.

In certain aspects, in addition to the thermoformed material providingabrasion resistance or traction or both to one or more areas of thearticle, the thermoformed material can provide structure, rigidity,strength, support, a water-proof or water-resistant surface, or anycombination thereof.

FIGS. 2A and 2B depict a shirt 200 as an exemplary article of apparel.The shirt 200 depicted in FIGS. 2A and 2B includes at least one textile,thermoformed textile, or thermoformed film component 202 that at leastpartly forms a portion of the shirt 200. As best seen in FIG. 2B, thetextile, thermoformed textile, or thermoformed film component 202 can bea textile or thermoformed textile which includes three separate textilezones 204, 206 a-d, and 208, which can identify specific functionalareas of the 200. In certain aspects, these specific functional areasare at least partly associated with the targeted incorporation ofspecific textile media in varying amounts and combinations into thesetextile zones 204, 206 a-d, and 208.

In certain aspects, the textile zone 204 can include a reinforced areasuch as an exterior-facing film or patch 210, which can, for example,provide abrasion resistance to an elbow region 212 of the shirt 200. Insuch aspects, the targeted integral incorporation of the films, fibers,filaments or yarns described herein into the textile zone 204 can atleast partly form the patch 210, when the textile 202 is thermoformed,by melting or deforming the films, fibers, filaments or yarns asdescribed herein and subsequent cooling and solidifying of the meltedfirst polymeric composition to form a patch 210.

In various aspects, the textile zone 208 can exhibit flexibility and/orpliability similar to a conventional shirt material. Further, in certainaspects, the textile zone 206 can at least partly provide a transitionwithin the textile 202 from the more rigid or semi-rigid patch 210present in textile zone 204 to the more flexible pliable portion presentin the textile zone 208. In such aspects, the textile zones 206 a-d caninclude a combination of the first film, fiber, filament or yarndescribed herein present in the textile zone 204 and the second film,fiber, filament or yarn present in the textile zone 208. While not shownin FIGS. 2A and 2B, the textile zones 206 b-d also provide a transitionto a flexible pliable material, such as that present in the textile zone208.

In certain aspects, like with the textile zone 106 of the textile 102discussed above with reference to FIGS. 1A and 1B, this combination ofthe first film, fiber, filament or yarn described herein from textilezone 204 and the second film, fiber, filament or yarn present fromtextile zone 208 can provide a seamless or integrated transition fromthe patch 210 to the flexible pliable portion found in textile zone 208of the shirt 200.

While this exemplary description in FIGS. 2A and 2B of the textile zones204, 206 a-d, and 208 relates to an elbow region of the article ofapparel 200, it should be understood that the textile zones 204, 206a-d, and 208 and associated properties can be applied to other areas ofa shirt or other articles of apparel, such as a knee, thigh, hip, chest,and/or lower back region of an article of apparel, or to areas requiringreinforcement such as areas adjacent to a fastener, for example, azipper, a button, a snap, a pull cord, and the like.

Turning now to FIG. 3, a plan view of a schematic textile 300 isprovided. It should be understood that the textile 300 can be any typeof textile known to one skilled in the art. A non-limiting list oftextiles that are suitable for use in the articles of wear and methodsdisclosed herein includes knit textiles, woven textiles, non-woventextiles, crocheted textiles, and braided textiles.

Similar to the textile 102 of FIGS. 1A and 1B, and the textile 202 ofFIGS. 2A and 2B, the textile 300 of FIG. 3 includes three types oftextile zones. For example, the textile 300 includes a textile zone 302that can include the first film, fiber, filament or yarn describedherein, textile zones 306 a and 306 b that can include the second film,fiber, filament or yarn, and textile zones 304 a and 304 b that caninclude a combination of films, fibers, or yarns compose of differentthermoplastic elastomers. In textile 300 of FIG. 3, the textile zones304 a and 304 b can be positioned on either side of textile zone 302,while textile zones 306 a and 306 b can be positioned on the oppositesides of the textile zones 304 and 304 b, respectively.

In certain aspects, the films, fibers, filaments, yarns, and textilesdescribed herein, when exposed to a thermoforming process, can impart astructural or functional property to an article of wear or sportingequipment. Further, the combination of first films, fibers, filaments,yarns described herein and second films, fibers, filaments, or yarns canprovide structural support and three-dimensional structure for aparticular article of wear or sporting equipment. Further, in certainaspects, this combination of films, fibers, filaments, yarns, andtextiles can provide an integrated transition between a rigidthermoformed material and flexible pliable fibers.

In certain aspects, based on the relative positioning of the firstfilms, fibers, filaments, yarns, and textiles described herein and thesecond films, fibers, filaments, or yarns in the in different zones ofthe textiles, thermoformed textiles and thermoformed film component, thezones can have varying concentration of the first and second films,fibers, filaments or yarns, and thus can have varying concentrations ofthe first polymeric composition and the second polymeric composition inthese zones.

As used herein, the term “concentration” refers to a clustering orcongregation in a specific volume. Thus, the term concentration includesmeasuring the amount (e.g., the weight in grams) of a material in aspecified volume (e.g., cubic centimeter). For example, in a knittextile, a first portion of a single knit layer of a textile can have anincreased concentration of a first yarn compared to a second portion ofthe textile by having more stitches (e.g., knit stitches, tuck stitches,and/or float stitches) of that first yarn than the second portion ofequal size. In another example, a first portion of a textile can includea greater concentration of an inlaid film, fiber, filament or yarn thana second portion. In another example, in a non-woven textile, a firstportion of the textile can have an increased concentration of a firstfiber if that textile was formed with more of the first fiber (e.g., aweight in grams) than a second portion of equal size.

In aspects, a textile, thermoformed textile, or thermoformed filmcomponent can include a first zone and a second zone, wherein the firstzone comprises at least 5 weight percent, or at least 10 weight percent,or at least 20 weight percent, or at least 30 weight percent more of thefirst polymeric composition than the second zone.

FIGS. 4A-4J depict exemplary potential knitting structures that can bepresent in in a knit textile or knit thermoformed textile as disclosedherein. FIG. 4A depicts a knit stitch (or sometimes referred to as aJersey stitch) structure 502 formed from a back needle bed 504. Itshould be understood that the row of small circles associated with theback needle bed 504, represents needles (e.g., a needle 505) of the backneedle bed 504, in accordance with traditional stitch schematics.Further, the same is true for a front needle bed, e.g., the front needlebed 508 depicted in FIG. 4B; that is, that the row of small circlesassociated with the front needle bed 508 represent needles (e.g., aneedle 507) in the front needle bed 508.

FIG. 4B depicts a knit stitch structure 506 formed from a front needlebed 508. FIG. 4C depicts a float and tuck stitch structure 510, withtuck stitches that are formed by a front needle bed 512 and a backneedle bed 514. FIG. 4D depicts another float and tuck stitch structure516, with tuck stitches formed by a front needle bed 518 and a backneedle bed 520. FIG. 4E depicts a float stitch structure 522. FIG. 4Fdepicts a knit and tuck stitch structure 524 having knit stitches 524 aformed by a back needle bed 528 and tuck stitches 524 b formed by afront needle bed 526. FIG. 4G depicts a knit and float stitch structure530, with the knit stitches formed on a front needle bed 532. FIG. 4Hdepicts a knit and float stitch structure 534, with the knit stitchesformed a back needle bed 536. FIG. 4I depicts a tuck and float knitstructure 538, with the tuck stitches formed by a front needle bed 540.FIG. 4J depicts a tuck and float knit structure 542, with the tuckstitches formed by a back needle bed 544.

In certain aspects, it can be desirable to bulk up the film, fiber,filament or yarn described herein in a particular region or zone, inorder to provide a desired thickness and rigidity to the article whenthermoformed, e.g., to form a ground-facing outsole of an article offootwear. In such aspects, when using a knit textile, the region or zonecan include repeat stitches or inlaid films, fibers, filaments or yarnsto increase the concentration of the first polymeric compositiondescribed herein relative to other zones.

In certain aspects, in regions of the textile 300 that include asubstantial amount of the first polymeric composition described herein,e.g., the textile zone 302, an anchor yarn can be provided in thetextile 300 to help restrict the flow of the melted first polymericcomposition described herein and/or to provide some flexibility to thezone once thermoformed. For example, the anchor yarn can be present inthe textile 300 as many different types of knit structure, such as oneor more of structures depicted in FIGS. 4E and 4G-J. In certain aspects,the stitch selection for the anchor yarn can depend upon the desiredresistance to elongation of the material through which the anchor yarnextends. For example, an anchor yarn stitch which floats five needlesbetween tuck or knit stitches would provide a greater resistance tostretch to the material through which the anchor yarn extends comparedto an anchor yarn stitch which only floats 2 or 3 needles between tuckor knit stitches. In such an example, the differing resistance toelongation between the length of the float is a result of non-linearportions (e.g., stitch loops) that are more prone to elongation thanlinear segments, which results in different amounts of resistance toelongation.

In such aspects, the anchor yarn can exhibit an elongation that is lessthan the elongation of the low processing temperature polymericcomposition, such as a yarn comprising the low processing temperaturepolymeric composition or a melted yarn component produced bythermoforming such a yarn. For example, in aspects, the anchor yarn canexhibit an elongation that is at least about 10% less than theelongation of a yarn comprising the low processing temperature polymericcomposition or a melted yarn component produced by thermoforming a yarncomprising the low processing temperature polymeric composition. In oneaspect, the anchor yarn can exhibit an elongation that at least about25% less than the elongation of a yarn comprising the low processingtemperature polymeric composition or a melted yarn component produced bythermoforming a yarn comprising the low processing temperature polymericcomposition. In another aspect, the anchor yarn can exhibit anelongation that at least about 50% less than the elongation of a yarncomprising the low processing temperature polymeric composition or amelted yarn component produced by thermoforming a yarn comprising thelow processing temperature polymeric composition. In yet another aspect,the anchor yarn can exhibit an elongation that at least about 75% lessthan the elongation of a yarn comprising the low processing temperaturepolymeric composition or a melted yarn component produced bythermoforming a yarn comprising the low processing temperature polymericcomposition. Exemplary anchor yarns include polyamide yarns, polyolefinyarns, and polyester yarns, including yarns having tenacities of fromabout 5 grams per denier to about 10 grams per denier.

As discussed above, the textiles described herein, which can includefibers and/or yarns comprising the film, fiber, filament or yarndescribed herein, can be thermoformed to impart some structure ofproperties to the article of wear. Further, as discussed above, thethermoforming process can cause at least a portion of the film, fiber,filament or yarn described herein present in the textile to melt ordeform and subsequently solidify.

FIG. 5A schematically depicts a portion 700 of the textile zone 304 a ofthe upper knit layer of the textile 300 of FIG. 3 prior to athermoforming process. The portion 700 includes a first course 702 and asecond course 704 having a first yarn 708. The portion also includes athird course 706 of a second yarn 710 that comprises the film, fiber,filament or yarn described herein. In such an aspect, the third course706 of loops of the second yarn 710 can be interconnected, e.g.,interlooped, to the first course 702 and the second course 707 havingthe first yarn 708. As used herein, “interlooped” refers to the how aloop from one course can wrap around a loop of another course such as ina knit stitch, and also refers to how one loop can have another segmentof yarn pulled through the loop (or through the loop and around the yarnforming the loop) in order to form a second loop, as in a crochetprocess.

FIG. 5B depicts the portion 700 after being exposed to a thermoformingprocess. As can be seen by comparing FIGS. 5A and 5B, the second yarn710 that comprises the film, fiber, filament or yarn described hereinwas thermoformed from a yarn material into a melted yarn component 712.In certain aspects, the heating step of the thermoforming process atleast partly caused the film, fiber, filament or yarn described hereinin the second yarn 710 to melt and flow and then subsequently solidifyby the completion of the thermoforming process into the melted yarncomponent 712.

In aspects, as can be seen in FIGS. 5A and 5B, the thermoforming processhas also transformed at least a portion of the knit structure of theportion 700 of the upper knit layer of the textile 300 of FIG. 3. Forexample, the courses 702, 704, and 706 depicted in FIG. 7A have beentransformed such that the portion 700 no longer includes interconnectedcourses of loops of a yarn comprising the film, fiber, filament or yarndescribed herein and a second yarn, at least partly due to thetransformation of the yarn 710 in the second course 706 to the meltedyarn component 712. As can be seen in FIG. 5B, although thethermoforming process can eliminate the interconnected loops in theportion 700 of the upper knit layer of the textile 300 of FIG. 3, theremaining course 702 and 704 can be connected by the melted yarncomponent 712. In such aspects, this portion 700 of upper knit layer ofthe textile 300 of FIG. 3 can fix the position of the courses 702 and704 to one another, as opposed to when the courses 702 and 704 wereinterconnected via the course 706 prior thermoforming. Further, in suchaspects, a top portion 714 of the loops of the first course 702 canstill be free to interconnect with other courses of yarn allowing one tomodulate the level of rigidity and/or three-dimensional forming providedby the textile zone 304 a.

FIG. 6 depicts a cross-section of the portion 700 of the upper knitlayer of the textile 300 of FIG. 3 along the cut line 8 illustrated inFIG. 5B. As can be seen in FIG. 6, at least portion of the first yarn708 can be encapsulated within the melted yarn component 712. Dependingon the conditions used during the thermoforming process, the melted yarncomponent 712 can solidify into a film-like structure surrounding atleast a portion of the loops of the first course 702 and the secondcourse 704 of the first yarn 708.

As can be seen in the aspect depicted in FIGS. 5B and 6, the first yarn708 did not melt or deform after being exposed to the thermoformingprocess. Further, in certain aspects, the first yarn 708 can contain adye 716 (depicted as the speckling within the first yarn 708) that doesnot leach out after being exposed to the thermoforming process. Forexample, as can be seen in FIGS. 5B and 6, there is no visible leachingof the dye 716 from the first yarn 708 into adjacent regions of themelted yarn component 712, e.g., the adjacent region 718. In certainaspects, at least about 80 weight percent, at least about 90 weightpercent, at least about 95 weight percent, or at least 99 weight percentof the dye 716 remains within the first yarn 708 or within thethermoformed portion 700 of the upper knit layer of the textile 300 ofFIG. 3. In the same or alternative aspects, upon thermoforming, there isno visible leaching of the dye into any additional materials associatedwith the final article of wear, which the portion 700 of upper knitlayer of the textile 300 of FIG. 3 textile 300 is incorporated into.

FIG. 7A shows a cross-sectional view of a textile as disclosed herein,prior to thermoforming, the textile having a first side 800, a secondside 802, and a core comprising coated yarns as disclosed herein, thecoated yarns further having a core yarn 804 and a coating comprising apolymeric composition 806. FIG. 7B shows the same textile followingthermoforming, where the core yarn 804 is disposed within the re-flowedand re-solidified polymeric composition 808 of the coated yarn.

FIG. 7C shows a cross-sectional view of a textile as disclosed herein,prior to thermoforming, the textile having a first side 800, a secondside 802, and a core comprising coated yarns as disclosed herein and anadditional second yarn 810 disposed on at least one side of the textile,the coated yarns further having a core yarn 804 and a coating comprisinga polymeric composition 806. FIG. 7D shows the same textile followingthermoforming, where the core yarn 804 is disposed within the re-flowedand re-solidified polymeric composition 808 of the coated yarn and thesecond yarn is disposed at the surface of the re-flowed andre-solidified polymeric composition.

FIG. 7A shows a cross-sectional view of a textile as disclosed herein,prior to thermoforming, the textile having a first side 800, a secondside 802, and a core comprising coated yarns as disclosed herein anadditional second yarn disposed on the first side and the second side ofthe textile 810, the coated yarns further having a core yarn 804 and acoating comprising a polymeric composition 806. FIG. 7B shows the sametextile following thermoforming, where the core yarn 804 is disposedwithin the re-flowed and re-solidified polymeric composition 808 of thecoated yarn and the second yarn is disposed at both surfaces of there-flowed and re-solidified polymeric composition.

The article can be an article of manufacture or a component of thearticle. The article of manufacture can include footwear, apparel (e.g.,shirts, jerseys, pants, shorts, gloves, glasses, socks, hats, caps,jackets, undergarments), containers (e.g., backpacks, bags), andupholstery for furniture (e.g., chairs, couches, car seats), bedcoverings (e.g., sheets, blankets), table coverings, towels, flags,tents, sails, and parachutes, or components of any one of these. Inaddition, the textile or articles including the textile can be used withor disposed items such as striking devices (e.g., bats, rackets, sticks,mallets, golf clubs, paddles, etc.), athletic equipment (e.g., golfbags, baseball and football gloves, soccer ball restriction structures),protective equipment (e.g., pads, helmets, guards, visors, masks,goggles, etc.), locomotive equipment (e.g., bicycles, motorcycles,skateboards, cars, trucks, boats, surfboards, skis, snowboards, etc.),balls or pucks for use in various sports, fishing or hunting equipment,furniture, electronic equipment, construction materials, eyewear,timepieces, jewelry, and the like.

The article can be an article of footwear. The article of footwear canbe designed for a variety of uses, such as sporting, athletic, military,work-related, recreational, or casual use. Primarily, the article offootwear is intended for outdoor use on unpaved surfaces (in part or inwhole), such as on a ground surface including one or more of grass,turf, gravel, sand, dirt, clay, mud, pavement, and the like, whether asan athletic performance surface or as a general outdoor surface.However, the article of footwear may also be desirable for indoorapplications, such as indoor sports including dirt playing surfaces forexample (e.g., indoor baseball fields with dirt infields).

In particular, the article of footwear can be designed for use in indooror outdoor sporting activities, such as global football/soccer, golf,American football, rugby, baseball, running, track and field, cycling(e.g., road cycling and mountain biking), and the like. The article offootwear can optionally include traction elements (e.g., lugs, cleats,studs, and spikes as well as tread patterns) to provide traction on softand slippery surfaces, where components of the present disclosure can beused or applied between or among the traction elements and optionally onthe sides of the traction elements but on the surface of the tractionelement that contacts the ground or surface. Cleats, studs and spikesare commonly included in footwear designed for use in sports such asglobal football/soccer, golf, American football, rugby, baseball, andthe like, which are frequently played on unpaved surfaces. Lugs and/orexaggerated tread patterns are commonly included in footwear includingboots design for use under rugged outdoor conditions, such as trailrunning, hiking, and military use.

In particular, the article can be an article of apparel (i.e., agarment). The article of apparel can be an article of apparel designedfor athletic or leisure activities. The article of apparel can be anarticle of apparel designed to provide protection from the elements(e.g., wind and/or rain), or from impacts.

In particular, the article can be an article of sporting equipment. Thearticle of sporting equipment can be designed for use in indoor oroutdoor sporting activities, such as global football/soccer, golf,American football, rugby, baseball, running, track and field, cycling(e.g., road cycling and mountain biking), and the like.

FIGS. 8A-8Q illustrate various articles which can comprise a textile ofthe present disclosure, including a thermoformed textile of the presentdisclosure. As illustrated in FIGS. 8A-8Q, hashed areas are positionedon various regions and structures of the articles. These hashed areasare intended to illustrate general regions and structures which cancomprise a textile of the present disclosure, and are not necessarilyintended to be representative of the size of the surface area of theregion or surface defined by a surface of the textile. In some aspects,the hashed areas indicate a surface of a region or a surface of astructure which can be defined by the thermoplastic network of athermoformed textile in accordance with the present disclosure. In oneaspect, the surface defined by the thermoplastic network can have atotal surface area of at least one square centimeter. In another aspect,the surface defined by the thermoplastic network comprises a polymericcomposition of a coated yarn in re-flowed and re-solidified form.

FIGS. 8A-8M illustrates footwear, apparel, athletic equipment,container, electronic equipment, and vision wear that include thetextile of the present disclosure, including a thermoformed textile ofthe present disclosure. The structure including the textile isrepresented by hashed areas 12A′/12M′-12A″/12M′. The location of thestructure is provided only to indicate one possible area that thestructure can be located. Also, two locations are illustrated in some ofthe figures and one location is illustrated in other figures, but thisis done only for illustration purposes as the items can include one or aplurality of structure, where the size and location can be determinedbased on the item.

FIGS. 8N(a)-8N(b) illustrate a perspective view and a side view of anarticle of footwear 100 that include a sole structure 1004 and an upper1002. The structure including the textile is represented by 1022 a and1022 b. The sole structure 1004 is secured to the upper 1002 and extendsbetween the foot and the ground when the article of footwear 1000 isworn. The primary elements of the sole structure 1004 are a midsole 1014and an outsole 1012. The midsole 1014 is secured to a lower area of theupper 1002 such as a strobel (not shown) and may include a cushioningelement comprising a resilient material such as a polymer foam oranother appropriate material. In other configurations, the cushioningelement of the midsole 1014 can incorporate fluid-filled chambers,plates, moderators, and/or other elements that further attenuate forces,enhance stability, or influence motions of the foot. The outsole 1012 issecured to a lower surface of the midsole 1014 and may comprise awear-resistant elastomeric material such as a natural or syntheticrubber material. The outsole can be textured to impart traction, or caninclude one or more traction elements. The traction elements can beseparate elements affixed to the outsole, or can be integrally formedwith the outsole The upper 1002 can be formed from various elements(e.g., lace stays, tongue, collar, medial side, lateral side, vamp, toebox, heel counter) that combine to provide a structure for securely andcomfortably receiving a foot. Although the configuration of the upper1002 may vary significantly, the various elements generally define avoid within the upper 1002 for receiving and securing the foot relativeto sole structure 1004. Surfaces of the void within upper 1002 areshaped to accommodate the foot and can extend over the instep and toeareas of the foot, along the medial and lateral sides of the foot, underthe foot, and around the heel area of the foot. The upper 1002 can bemade of one or more materials such as films, textiles, cables, yarns,fibers, foams, natural leathers, synthetic leathers, and the like thatare knitted, stitched, bonded or otherwise connected together. Althoughthis configuration for the sole structure 1004 and the upper 1002provides an example of a sole structure that may be used in connectionwith an upper, a variety of other conventional or nonconventionalconfigurations for the sole structure 1004 and/or the upper 1002 canalso be utilized. Accordingly, the configuration and features of thesole structure 1004 and/or the upper 1002 can vary considerably.

FIGS. 8O(a) and 8O(b) illustrate a perspective view and a side view ofan article of footwear 1030 that include a sole structure 1034 and anupper 1032. The structure including the textile is represented by 1036 aand 1036 b/1036 b′. The sole structure 1034 is secured to the upper 1032and extends between the foot and the ground when the article of footwear1030 is worn. The upper 1032 can be formed from various elements (e.g.,lace, tongue, collar) that combine to provide a structure for securelyand comfortably receiving a foot. Although the configuration of theupper 1032 may vary significantly, the various elements generally definea void within the upper 1032 for receiving and securing the footrelative to the sole structure 1034. Surfaces of the void within theupper 1032 are shaped to accommodate the foot and can extend over theinstep and toe areas of the foot, along the medial and lateral sides ofthe foot, under the foot, and around the heel area of the foot. Theupper 1032 can be made of one or more materials such as textilesincluding natural and synthetic leathers, molded polymeric components,polymer foam and the like that are stitched or bonded together.

The primary sole components of the sole structure 1034 can include aforefoot component 1042, a heel component 1044, and an outsole 1046.Each of the forefoot component 1042 and the heel component 1044 can bedirectly or indirectly secured to a lower area of the upper 1032. Insome aspects, the outsole 1046 may include one or both of anintegrally-formed heel component and forefoot component (not shown). Thesole component can comprise a polymeric material that encloses a fluid,which may be a gas, liquid, or gel. During walking and running, forexample, the forefoot component 1042 and the heel component 1044 maycompress between the foot and the ground, thereby attenuating groundreaction forces. That is, the forefoot component 1042 and the heelcomponent 1044 may be inflated and/or may be pressurized with the fluidto cushion the foot. In aspects where the outsole 1046 is a separatesole component, the outsole 1046 can be secured to lower areas of theforefoot component 1042 and the heel component 1044 and may be formedfrom a wear-resistant material that is textured to impart traction. Thesole component, such as a forefoot component 1042 or a heel component1044 or a combination forefoot and heel component (not shown), cancomprise one or more polymeric materials (e.g., a film comprising layersof one or more polymeric materials) that form one or more chambers thatincludes a fluid such as a gas. When the sole component comprises aplurality of chambers, the plurality of chambers can be independent orfluidically interconnected. In some configurations, the sole structure1034 may include a foam material forming at least one layer or region ofthe sole structure, for example, a layer or region that extends betweenthe upper 1032 and one or both of the forefoot component 1042 and theheel component 1044, or a foam region may be located within indentationsin the lower areas of the forefoot component 1042 and the heel component1044. In other configurations, the sole structure 1032 may incorporateplates, moderators, lasting elements, or motion control members thatfurther attenuate forces, enhance stability, or influence the motions ofthe foot, for example. In some configurations, the sole structure orsole component can consist essentially of one or more plates comprisingone or more traction elements, such as a single plate extending from thetoe to the heel of the upper, or two or more plates, where a singleplate is directly or indirectly affixed to a tip of the region of theupper, a forefoot region of the upper, a midfoot region of the upper, aheel region of the upper, or any combination thereof. Although thedepicted configuration for the sole structure 1034 and the upper 1032provides an example of a sole structure that may be used in connectionwith an upper, a variety of other conventional or nonconventionalconfigurations for the sole structure 1034 and/or the upper 1032 canalso be utilized. Accordingly, the configuration and features of thesole structure 1034 and/or the upper 1032 can vary considerably.

FIG. 8O(c) is a cross-sectional view of A-A that depicts the upper 1032and the heel component 1044. The textile 1036 b can be disposed on theexternally-facing surface of the heel component 1044 or alternatively oroptionally the textile 1036 b′ can be disposed on the internally-facingside of the heel component 1044.

FIGS. 8P(a) and 8P(b) illustrate a perspective view and a side view ofan article of footwear 160 that includes traction elements 1068. Thestructure including the textile is represented by 1072 a and 1072 b. Thearticle of footwear 1060 includes an upper 1062 and a sole structure1064, where the upper 1062 is secured to the sole structure 1064. Thesole structure 1064 can include one or more of a toe plate 1066 a, amid-foot plate 1066 b, and a heel plate 1066 c. The plate can includeone or more traction elements 1068, or the traction elements can beapplied directly to a ground-facing surface of the article of footwear.As shown in FIGS. 8P(a) and (b), the traction elements 1068 are cleats,but the traction elements can include lugs, cleats, studs, and spikes aswell as tread patterns to provide traction on soft and slipperysurfaces. In general, the cleats, studs and spikes are commonly includedin footwear designed for use in sports such as global football/soccer,golf, American football, rugby, baseball, and the like, while lugsand/or exaggerated tread patterns are commonly included in footwear (notshown) including boots design for use under rugged outdoor conditions,such as trail running, hiking, and military use. Footwear designed forrunning on paved surfaces commonly include tread patterns. The solestructure 1064 is secured to the upper 1062 and extends between the footand the ground when the article of footwear 1060 is worn.

FIGS. 8Q(a)-8Q(j) illustrate additional views of exemplary articles ofathletic footwear including various configurations of upper 1076. FIG.8Q(a) is an exploded perspective view of an exemplary article ofathletic footwear showing insole 1074, upper 1076, optional midsole oroptional lasting board 1077, and outsole 1078, which can take the formof a plate. Structures including the disclosed textiles are representedby 1075 a-1075 d. FIG. 8Q(b) is a top view of an exemplary article ofathletic footwear indicating an opening 183 configured to receive awearer's foot as well as an ankle collar 1081 which may include textile1082. The ankle collar is configured to be positioned around a wearer'sankle during wear, and optionally can include a cushioning element. Alsoillustrated are the lateral side 1080 and medial side 1079 of theexemplary article of athletic footwear. FIG. 8Q(c) is a back view of thearticle of footwear depicted in FIG. 8Q(b), showing an optional heelclip 1084 that can include textile 1085. FIG. 8Q(d) shows a side view ofan exemplary article of athletic footwear, which may optionally alsoinclude a tongue 1086, laces 1088, a toe cap 1089, a heel counter 1090,a decorative element such as a logo 1091, and/or eyestays for the laces1092 as well as a toe area 1093 a, a heel area 1093 b, and a vamp 1093c. In some aspects, the heel counter 1090 can be covered by a layer ofknitted, woven, or nonwoven fabric, natural or synthetic leather, film,or other shoe upper material. In some aspects, the eyestays 1092 areformed as one continuous piece; however, they can also comprise severalseparate pieces or cables individually surrounding a single eyelet or aplurality of eyelets. Structures including the disclosed textiles arerepresented by 1087 a-1087 e. While not depicted, the disclosed textilescan be present on the eyestays 1092 and/or the laces 1088. In someconfigurations, the sole structure can include a sole structure, such asa midsole having a cushioning element in part or substantially all ofthe midsole, and the textile can be disposed on an externally-facingside of the sole structure, including on an externally-facing side ofthe midsole. FIG. 8Q(e) is a side view of another exemplary article ofathletic footwear. In certain aspects, the upper can comprise one ormore containment elements 1094 such as wires, cables or molded polymericcomponent extending from the lace structure over portions of the medialand lateral sides of the exemplary article of athletic footwear to thetop of the sole structure to provide lockdown of the foot to the solestructure, where the containment element(s) can have a textile (notshown) disposed on an externally-facing side thereon. In someconfigurations, a rand (not shown) can be present across part or all ofthe biteline 1095.

Processes for Manufacturing

Certain conventional thermoforming processes include the selectivethermoforming of only a portion of an article, e.g., by masking portionsof the article not desired to be exposed to the thermoforming process,or using tooling which contacts or covers only a portion of an article.However, such conventional methods result in time and energy intensivemanufacturing processes, as multiple steps are required to mask andunmask portions of the article before and after the thermoformingprocess, or multiple sets of tooling are required. Other conventionalthermoforming processes include the thermoforming of article componentsprior to assembly into an article. This conventional process is also atime and resource intensive process, as multiple steps and machinery arerequired to individually form the article components prior to assemblingthe article. Moreover, an article formed from several individualcomponents results in multiple seams where the individual componentsinterface, thereby providing weaknesses in the article, less naturalfeel for a wearer, and/or actual discomfort or injury for a wearer.

The manufacturing processes disclosed herein solve one or more of theforegoing problems. The manufacturing processes disclosed herein utilizeone or more of the films, textiles, yarns and fibers disclosed herein.For example, in certain aspects, as discussed further below, thespecific and selective incorporation of the film, fiber, filament, yarn,or textile as described herein into an article provides a way to programstructural features into an article that can be formed uponthermoforming. In some aspects, the article can comprise a textilecomprising the film, fiber, filament or yarn as described herein, e.g.,a textile comprising at least one plurality of fibers or yarn comprisinga film, fiber, filament or yarn as described herein in at least aportion of the textile. In another aspect, the article can comprise afirst shaped article comprising a film, fibers, filaments, textile, yarnas described herein, and a second shaped component, film, textile, yarnor plurality of fibers, e.g., a knit upper for an article of footwearand a film as described herein. In further aspects, the article cancomprise an aggregation of components at least a portion of whichcomprise a film, fiber, filament or yarn as described herein and asecond fiber, upon which the disclosed thermoforming process has beenapplied.

Since, in aspects, such structural features are built into the articledepending upon the location in the article of the film, fiber, filamentor yarn as described herein, upon thermoforming these structuralfeatures become integrated with each other, allowing for a more naturalfeel for the wearer or user. For example, a knit program for electronicknitting equipment can used to determine the location of structuralfeatures. However, as already noted, the manufacturing processes (andadvantages associated with these processes) is not limited to the use ofthe textiles disclosed herein. For example, a process to form structuralfeatures in a disclosed article can utilize a film as described hereinwith a textile is also contemplated as a process to program structuralfeatures into a disclosed article. Alternatively, a process toeffectively program structural features into a disclosed article canutilize a shaped component comprising a film, fiber, filament or yarn asdescribed herein with a textile.

Additionally, this selective incorporation of the film, fiber, filamentor yarn as described herein into an article provides for a streamlinedmanufacturing process. For example, in certain aspects, an entirearticle can be formed by arranging components and exposing the arrangedcomponents to a thermoforming process, where the components that includethe film, fiber, filament or yarn as described herein melt, flow, andre-solidify into a more rigid structural feature, while the componentsthat include a film, fiber, filament or yarn as not provided herein donot deform during the thermoforming process. In such aspects, thisallows for the entire article to be exposed to the thermoforming processwithout the need to mask or protect areas that the manufacturer does notwish to melt, flow, and re-solidify, thereby resulting in a more timeand energy efficient manufacturing process. Further, in some cases, useof the articles described herein in the manufacturing processesdescribed herein also allows for several different structural or otheradvantageous features to be provided in the article without the need tocombine individual components into the final article, since suchfeatures can be built into the article at the textile level using thefilm, fiber, filament or yarn as described herein.

In various aspects, the thermoforming process occurs at a temperatureabove the melting temperature of the thermoplastic elastomer present inthe films, fibers, yarns and textiles described herein. In an aspect,thermoforming generates a “consolidated” textile. In one aspect, aconsolidated textile comprises a thermoformed network of yarnscomprising a first core yarn and a first polymeric composition, whereinthe first polymeric composition consolidates the thermoformed network ofyarns by surrounding at least a portion of the first core yarn andoccupying at least a portion of spaces between yarns in the thermoformednetwork of yarns, and wherein the first polymeric composition is athermoplastic elastomeric composition. In another aspect, thethermoformed network of yarns is the thermoformed product of a firsttextile comprising a first network of yarns including a first coatedyarn comprising the first core yarn and a first coating, where the firstcoating includes the first polymeric composition and wherein, in thethermoformed network, the first polymeric composition consolidating thethermoformed network of yarns is the re-flowed and re-solidified productof the first polymeric composition of the first coating of the firstcoated yarn. In some aspects, the thermoformed network of yarns is thethermoformed product of a first textile as described herein.

Also disclosed is a method of making a textile, the method comprisingforming a first network of yarns including a first coated yarn, thefirst coated yarn comprising a first core yarn and a first coatingincluding a first polymeric composition disposed on at least a portionof an outer surface of the first core yarn, wherein the first polymericcomposition is a thermoplastic elastomeric composition, thereby forminga thermoformed network of yarns comprising the first core yarn and thefirst polymeric composition, wherein the first polymeric compositionconsolidates the thermoformed network of yarns by surrounding at least aportion of the first core yarn and occupying at least a portion of thespaces between yarns in the thermoformed network of yarns.

In a further aspect, in a consolidated textile, the first polymericcomposition surrounds external surfaces of at least a portion of theyarn or yarns forming the textile, the first polymeric compositionoccupies spaces between the yarns, and the first polymeric compositionforms attachments between the yarns, such that the stretch of thetextile is reduced. In one aspect, the reduction in stretch can be alongjust one axis of the consolidated textile (e.g., an x axis, a y axis, ora bias axis at a 45 degree angle to the x and y axes) or along more thanone axis of the consolidated textile.

In certain aspects, the core yarn can be a monofilament or multifilamentyarn. The yarns can be based on natural or manmade fibers includingpolyester, high tenacity polyester, polyamide yarns, metal yarns,stretch yarns, carbon yarns, glass yarns, polyethylene or polyolefinyarns, bi-component yarns, PTFE yarns, ultra-high-molecular-weightpolyethylene (UHMWPE) yarns, liquid crystal polymer yarns, specialtydecorative yarns or reflective yarns or a multi-component yarncomprising one or more of the yarns.

In various aspects, the polymeric composition can further comprise anadditive, such as, but not limited to, be one or more of a thickener,processing aid, a dye or colorant. In a further aspect, the additive isnot optional and comprises at least one thickener. In a still furtheraspect, the additive is not optional and comprises at least oneprocessing aid. In yet a further aspect, the additive is not optionaland comprises at least one thickener and at least one processing aid. Incertain aspects, the thickener can comprise an inorganic material suchas silica, talc, or calcium carbonate (CaCO₃).

In certain aspects, as described herein, a thickener can be used duringthe preparation of the first polymeric composition (i.e., coatingcomposition) in order to improve productivity and matting properties. Ina further aspect, the thickener is silica powder, talc, or CaCO₃. Thethickener acts, at least in part, to increase the viscosity of the firstpolymeric composition.

In certain aspects, the first polymeric composition can comprise aprocessing agent in order to improve productivity. In a further aspect,the processing agent can be montane wax or a fatty acid ester (C5-C9)with pentaerythritol.

In certain aspects, the coated yarn having a desired color can beproduced by adding a master batch corresponding to the desired colorduring production of the first polymeric composition for coating yarn.In a further aspect, a TPU compound for coating yarn, which has adesired hardness, can be prepared by controlling the content of rawmaterial. In a still further aspect, the thickness of coated yarn can bereduced depending on the thickness of yarn made of polyester, nylon,spandex or the like.

In various aspects, the first polymeric composition for coating yarn hasa cold Ross flex test result of about 120,000 to about 180,000, or ofabout 140,000 to about 160,000, or of about 130,000 to about 170,000when tested on a thermoformed plaque of the first polymeric compositionfor coating yarn in accordance with the cold Ross flex test as describedherein below.

In certain aspects, the coated yarn can be prepared by compounding in aconventional extruder the first polymeric composition, and optionallyalso including one or more additives, and then coating the compoundedfirst polymeric composition on the surface of the core yarn. In afurther aspect, the process for preparing the coated yarn comprises thesteps of: 1) preparing formed thermoplastic pellets; and 2) producingcoated yarn. The formed thermoplastic pellets can be prepared by themethod disclosed herein, prepared by similar methods as known to theskilled artisan, or obtained from a commercially available source.

The step of preparing formed thermoplastic pellets can comprise thefollowing steps: 1) mixing a thermoplastic elastomer with variousadditives, e.g., a thickener and/or a processing aid, and feeding themixture into the hopper of a conventional compounding extruder; 2)melting, kneading and compounding the mixture in the cylinder of thecompounding extruder at a suitable temperature and pressure; 3) cuttingthe compounded thermoplastic elastomer, discharged through the dice ofthe compounding extruder, in cooling water to form pellets; and 4)drying the formed thermoplastic elastomer pellets at a suitabletemperature for about period of time and aging the dried pellets at asuitable temperature for a suitable period of time.

In a particular example, the step of preparing formed thermoplasticpellets comprises the steps of: 1) mixing thermoplastic elastomer withvarious additives, e.g., a thickener and/or a processing aid, andfeeding the mixture into the hopper of a conventional compoundingextruder; 2) melting, kneading and compounding the mixture in thecylinder of the compounding extruder at a temperature of about 150-250degrees Celsius and a pressure of about 50-150 kgf; 3) cutting thecompounded thermoplastic elastomer, discharged through the dice of thecompounding extruder, in cooling water to form pellets; and 4) dryingthe formed thermoplastic elastomer pellets at a temperature of 60-80degrees Celsius for about 4-6 hours and aging the dried pellets at atemperature of 30-50 degrees Celsius for about 7 days or more.

In certain aspects, the step of producing the coated yarn can comprisethe following steps: 1) mixing the formed thermoplastic elastomerpellets, prepared as described above, with a master batch correspondingto a desired color and feeding the mixture into the hopper of a yarncoating extruder; 2) melting the mixture of the formed thermoplasticelastomer pellets and the master batch in the cylinder of the yarncoating extruder at a suitable temperature and a suitable pressure; 3)coating the compounded thermoplastic elastomer and master batch on thesurface of yarn passing through a nipple and a dice to produce coatedyarn; and 4) winding the coated yarn around a bobbin using a windingmachine.

In one aspect, the coated yarn can have a thermal shrinkage of from 0 to20 percent, optionally of from 0 to 15 percent, or of from 0 to 10percent, measured as described in the Property Analysis andCharacterization Procedures. In another aspect, the coated yarn can havea tenacity of from about 1 gram per denier to about 10 grams per denier,optionally of about 2 grams per denier to about 8 grams per denier, orof about 2.5 grams per denier to about 5 grams per denier, measured asdescribed in the Property Analysis and Characterization Procedures. Instill another aspect, the coated yarn can have a strain at break of from0 to 20 percent, optionally of from 0 to 15 percent, or of 0 to 10percent, measured as described in the Property Analysis andCharacterization Procedures. In any of these aspects, thermal shrinkage,tenacity, and strain at break relate to the suitability of yarns forcommercial knitting machines. In a further aspect, coated yarns havingthe disclosed properties are suitable for commercial knitting.

In particular, the step of producing the coated yarn can comprise thefollowing steps: 1) mixing the formed thermoplastic elastomer pelletswith a master batch corresponding to a desired color and feeding themixture into the hopper of a yarn coating extruder; 2) melting themixture of the formed thermoplastic elastomer pellets and the masterbatch in the cylinder of the yarn coating extruder at a temperature ofabout 150-250 degrees Celsius. and a pressure of about 50-150 kgf; 3)coating the compounded thermoplastic elastomer and master batch on thesurface of yarn passing through a nipple and a dice to produce coatedyarn; and 4) winding the coated yarn around a bobbin using a windingmachine.

In one aspect, the yarn is a coated yarn comprising a core yarncomprising a second polymeric composition and a coating layer disposedon the core yarn, the coating layer comprising the first polymericcomposition, wherein the first polymeric composition has a first meltingtemperature, wherein the second polymeric composition is a secondthermoplastic composition having a second deformation temperature, andthe second deformation temperature is at least 20 degrees Celsiusgreater, optionally at least 50 degrees Celsius greater, optionally atleast 75 degrees Celsius greater, or optionally at least 100 degreesCelsius greater than the first melting temperature of the firstpolymeric composition.

In one aspect, the yarn is a coated yarn comprising a core yarncomprising a second polymeric composition and a coating layer disposedon the core yarn, the coating layer comprising the first polymericcomposition, wherein the first polymeric composition has a first meltingtemperature, wherein the second polymeric composition is a secondthermoplastic composition having a second deformation temperature, andthe second deformation temperature is at least 20 degrees Celsiusgreater than the first melting temperature of the first polymericcomposition, wherein the second polymeric composition is a firstthermoset composition.

In one aspect, the yarn is a coated yarn comprising a core yarncomprising a second polymeric composition and a coating layer disposedon the core yarn, the coating layer comprising the first polymericcomposition, wherein the first polymeric composition has a first meltingtemperature, wherein the second polymeric composition is a secondthermoplastic composition having a second deformation temperature, andthe second deformation temperature is at least 20 degrees Celsiusgreater than the first melting temperature of the first polymericcomposition, wherein the second polymeric composition is a firstthermoset composition, and wherein the difference between the seconddeformation temperature and the first melting temperature is at least 20degrees Celsius, at least 50 degrees Celsius, at least 75 degreesCelsius, or at least 100 degrees Celsius.

In various aspects, the thermoforming process occurs at a temperatureabove the first melting temperature of the first polymeric compositionbut below the deformation temperature of the second polymericcomposition. In this aspect, the core yarn (i.e., the second polymericcomposition) does not deform or soften during the coating process.

In various aspects, the thermoforming process occurs at a temperaturebelow the deformation temperature of the second polymeric compositionthat has been dyed so that such dye does not leach out of the yarn orfiber and into the surround during the thermoforming process. Thus, inorder to form various textiles and articles described herein, thedeformation temperature of the second polymeric composition is below atemperature used to dye the core fiber.

In particular examples, the films, fibers, filaments, and yarnsdescribed herein have melting characteristics and acceptable levels ofshrinkage when present in a yarn and used in commercial knittingequipment.

Accordingly, in one aspect, a process for manufacturing an article isprovided. The article can be a component of an article of footwear, acomponent of an article of apparel, or is a component of an article ofsporting equipment. For example, a component of an article of sportingequipment can be a hat, a component of a bag, a component of a ball, anda component of protective equipment.

In one aspect, the process for manufacturing the article includesplacing a first film, fiber, filament or yarn as described herein, or atextile as described herein on a surface; while the first film, fiber,filament, yarn or textile is on the surface, increasing a temperature ofthe first film, fiber, filament, yarn or textile to a temperature thatis above the melting temperature of the first polymeric composition; andsubsequent to the increasing the temperature, while the first film,fiber, filament, yarn or textile remains on the surface, decreasing thetemperature to a temperature below the melting temperature of the firstpolymeric composition, thereby forming a article.

In one aspect, disclosed herein is a method for making an articlecomprising affixing a first textile to a second component, wherein thefirst textile comprises a first network of yarns including a firstcoated yarn, the first coated yarn comprising a first core yarn and afirst coating including a first polymeric composition disposed on atleast a portion of an outer surface of the first core yarn, wherein thefirst polymeric composition is a thermoplastic elastomeric composition.In another aspect, disclosed herein is a method of making an article,the method comprising thermoforming a first textile, wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition andwherein the thermoforming comprises melting, reflowing, andre-solidifying the first polymeric composition within the first textile,forming a thermoformed textile comprising a thermoformed network ofyarns comprising the first core yarn and the first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns. In still another aspect, disclosedherein is a method for making an article, the method comprising affixinga first textile to a second component, wherein the first textilecomprises a thermoformed network of yarns comprising a first core yarnand a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition. In some aspects, the method for making thearticle further includes the process of making a textile as disclosedherein. Also disclosed are articles made by the disclosed methods andprocesses.

In one aspect, a method for making an upper for an article of footwearis provided, the method comprising affixing a first textile to a secondcomponent, wherein the first textile comprises a first network of yarnsincluding a first coated yarn, the first coated yarn comprising a firstcore yarn and a first coating including a first polymeric compositiondisposed on at least a portion of an outer surface of the first coreyarn, wherein the first polymeric composition is a thermoplasticelastomeric composition. In another aspect, disclosed herein is a methodfor making an upper for an article of footwear, the method comprisingthermoforming an upper comprising a first textile, wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition andwherein the thermoforming comprises melting, reflowing, andre-solidifying the first polymeric composition with n the first textile,forming a thermoformed textile comprising a thermoformed network ofyarns comprising the first core yarn and the first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns. In still another aspect, disclosedherein is a method for making an upper for an article of footwear, themethod comprising affixing a first textile to a second component,wherein the first textile comprises a thermoformed network of yarnscomprising a first core yarn and a first polymeric composition, whereinthe first polymeric composition consolidates the thermoformed network ofyarns by surrounding at least a portion of the first core yarn andoccupying at least a portion of spaces between yarns in the thermoformednetwork of yarns, and wherein the first polymeric composition is athermoplastic elastomeric composition. Also disclosed are uppers made bythe disclosed methods and processes.

In some aspects, more than one coating can be applied to the yarnsdisclosed herein. In one aspect, disclosed herein are yarns containingan optional second coating and/or an optional third coating. In someaspects, the first coating is applied to the entirety of the core yarnand the second and/or third coatings are applied on top of the firstcoating. In other aspects, the first coating is applied to only aportion of the core yarn and the second and/or third coatings areapplied to portions of the core yarn uncoated by the first coating. Inany of these aspects, when the second coating and/or the third coatingis polymeric, the second coating and/or third coating displays meltingcharacteristics similar to those of the first coating. In some aspects,the second coating and/or the third coating melts at a lower temperaturethan the T_(m) of the first coating.

In another aspect, a process for making a midsole-outsole unit for anarticle of footwear is provided. The process includes affixing a midsolecushioning element and an outsole component for an article of footwearto each other, wherein the first polymeric composition defines at leasta portion of an outer surface of the outsole configured to beground-facing or ground-contacting.

In another aspect, a process for manufacturing an upper for an articleof footwear is provided. In one aspect, the method involves affixing anupper and an outsole to each other to form the article of footwear,wherein the first polymeric composition defines at least a portion of anouter surface of the upper.

In another aspect, a process for manufacturing an outsole for an articleof footwear is provided. In one aspect, the method involves affixing anupper and an outsole to each other to form the article of footwear,wherein the first polymeric composition defines at least a portion of anouter surface of the outsole configured to be ground-facing orground-contacting.

In another aspect, a process for manufacturing a midsole-outsole unitfor an article of footwear comprising a midsole cushioning element andan outsole element is provided. In one aspect, the method involvesaffixing an upper and an outsole to each other to form the article offootwear, wherein the first polymeric composition defines at least aportion of an outer surface of the midsole-outsole unit configured to beground-facing or ground-contacting.

In another aspect, a process for making an upper for an article ofapparel is provided. The process includes weaving a first course thatincludes interlacing a first yarn and a second yarn. The first and/orsecond yarn includes a film, fiber, filament or yarn as describedherein. In some aspects, at least a portion of the first yarn is a warpyarn; and wherein at least a portion of the second yarn is a weft yarn.In alternative aspects, at least a portion of the first yarn is a weftyarn; and wherein at least a portion of the second yarn is a warp yarn.In one aspect, when the textile is a woven textile, the first network ofyarns includes interlaced sets of yarns comprising the first coated yarnin a warp direction, or in a weft direction, or in both the warp andweft directions.

In a still further aspect, a process for manufacturing an upper for ashoe is provided. The process includes receiving an upper that includesa first yarn and a second yarn. The first and/or second yarn includes afilm, fiber, filament or yarn as described herein. In a first portion ofthe upper, at least one of the first yarn and the second yarn form aplurality of interconnected loops. The process also includes placing theupper on a last. Further, the process includes heating the entire upper,while on the last, to a temperature that is above the meltingtemperature of the thermoplastic elastomer present in the film, fiber,filament or yarn described herein. Subsequent to the heating the entireupper, cooling the entire upper, while on the last, to a temperaturebelow the melting temperature of the thermoplastic elastomer, to therebyform a thermoformed upper.

In yet another aspect, a process for manufacturing an upper for a shoeis provided. The process includes receiving an upper including one ormore first film, fiber, filament or yarns as described herein and one ormore second films, fibers, or yarns. The upper includes a ground-facingoutsole area, and wherein at least a portion of the one or more firstfibers is present on the ground-facing outsole area. The process furtherincludes placing the upper on a last such that at least a portion of theground-facing outsole area covers at least a portion of a bottom of thelast. The process also includes heating the entire upper, while on thelast, to a temperature that is above the melting temperature of thethermoplastic elastomer present in the film fibers, or yarn describedherein. Subsequent to the heating the entire upper, cooling the entireupper, while on the last, to a temperature below the melting temperatureof the thermoplastic elastomer, to thereby form a thermoformed upper.

In a yet further aspect, a process for making a knit upper for anarticle of footwear is provided. The process includes knitting a firstcourse that includes loops of a first yarn and a second yarn. The firstyarn included a film, fibers, filaments, or yarn as described herein.The process further includes knitting a second course that comprisesloops of the first yarn and the second yarn. At least a portion of thefirst course and at least a portion of the second course form aplurality of interconnected loops.

In one aspect, the first yarn and second yarn can be knitted to form atextile. Following textile formation, it can, in some aspects, bedesirable to add additional polymeric components directly to the knittedtextile. In one aspect, additional polymeric components can be used toform components of an article of footwear such as soccer boot lug tips,an outsole, a rand, or another component. In one aspect, the additionalpolymeric components can have the same composition as the coatingcomposition disclosed herein but are not incorporated as yarn coatings.In a further aspect, the additional polymeric components can beprocessed by another method such as injection overmolding. In oneaspect, the molten injection component is miscible with and adheres wellto the knit textile without the need for primer or adhesive bondingpreparation since the molten injection component and the yarn coatingcomposition have the same chemical composition.

The method steps, processes, and operations described herein are not tobe construed as necessarily requiring their performance in theparticular order discussed or illustrated, unless specificallyidentified as an order of performance. Additional or alternative stepscan be employed.

Exemplary Pre-Thermoforming and Thermoforming Processes

As discussed above, in certain aspects, the articles and textilesdescribed above, e.g., the textile 300 of FIG. 3, can form at least aportion of an article of wear, such as an article of footwear. In suchaspects, the textile can form an upper for the article of footwear,where the upper includes a ground-facing outsole portion.

In certain aspects, the article or textile can be combined withadditional materials in forming the upper for the article of footwear.For example, in one or more aspects, the textile can be combined orlayered with one or more of an ankle collar lining, ankle collar foam,upper lining, or upper foam layer. In certain aspects, one or more ofthese additional materials can be secured to the textile, e.g., byknitting, stitching, or adhesion, prior to thermoforming the textile.

In one aspect, the films, fibers, filaments, yarns and textiles can bethermoformed using a molding surface such as a flat plate or aconventional two-piece mold. The articles can be heated beforecontacting the molding surface or can be heated while contacting themolding surface. Optionally, pressure can be applied during or followingthe heating. When the articles are thermoformed in a flat form, theentire article does not need to be heated (e.g., portions can be masked,or a shaped heated element can be used).

In particular examples, the film, fiber, filament, yarn, textile, orfootwear component comprising the first polymeric composition disclosedherein can be thermoformed on a molding surface such as a last. In theexample where the article is a component footwear that includes an upperor a component of an upper, (e.g., is a textile that will become part ofan upper, is an upper, or is an upper and outsole unit), in order toprepare the article for the thermoforming process, the article is placedon a last such that the article wraps over a portion of the last, orlast enters the inside of the upper. For example, the article can wraparound the last to cover all of or a portion of: a bottom portion of thelast, a forefoot portion of the last, a heel portion of the last, or anycombination thereof. In certain aspects, the last can be formed of apolymeric material such as a high processing temperature polymercomposition. In a particular aspect, the last can be formed of apolymeric material having a melting temperature T_(m) or a degradationtemperature greater than 250 degrees Celsius or greater than 300 degreesCelsius such as, for example, a silicone polymer. The last can be madeof other types of material as long as such a material would not bedeformed or melt during the thermoforming process or otherwise adverselyaffect the thermoforming of the upper.

In certain aspects, a first layer can be placed on a molding surface,such as a last, before the article, such as an article of footwear orcomponent of an article of footwear. For example, a first layer, such asa liner, can be optionally placed over a molding surface, such as alast. Accordingly, a film, fiber, filament, yarn or textile according tothis disclosure is then placed such it covers at least a portion of theliner. Thus, at least a portion of the film, fiber, filament or yarn asdescribed herein is covering at least a portion of the liner.

In further aspects, an outer layer can be optionally positioned on atleast a portion of the article that is positioned on a molding surfaceand covering at least a portion of the article. The outer layer, whichcan comprise a film, fiber, filament, yarn or textile comprising thefirst polymeric composition, can be optionally placed over at least aportion of a textile or an article, such as an upper, that is positionedon a molding surface, such as a last. For example, a textile zone whichis associated with the ground-facing outsole portion of the upper cancover all or at least a portion of the bottom portion of the last, or atleast a portion of a textile or article in contact with the last.Accordingly, a textile zone associated with the upper can cover all orat least a portion of the upper region of the last or can cover all orat least a portion of a textile or upper in contact with the last. Thus,at least a portion of the film, fiber, filament, yarn, textile orcomponent comprising the first polymeric composition as described hereinis in contact with at least a portion of the outer layer, or forms atleast a portion of the outer layer.

In certain aspects, a shaped component, such as a heel counter or a toecap, can be optionally placed on an outer surface of an upper or acombination upper and outsole unit. Alternatively, a shaped component,such as a heel counter or a toe cap, can be optionally placed on aninner surface of an upper and thermoformed in contact therewith. It isunderstood that the placement of a shaped component, whether an outersurface of an upper or an inner surface of an upper, is completed beforeapplying a mask, protective sheath, a vacuum, or any combination thereofas described herein below.

In certain aspects, during the thermoforming process, the film, fiber,filament or yarn as described herein can melt and flow. In variousaspects, it can be desirable to mask regions of the article or restrictor direct the flow of the melted film, fiber, filament or yarn asdescribed herein, or both. In such aspects, a protective sheath can beapplied over the article positioned on a molding surface. For example, aprotective sheath can be positioned over an upper positioned on a last.In certain aspects, the protective sheath can be formed of a polymericmaterial having a melting temperature greater than that of the secondpolymeric composition. In a particular aspect, the protective sheath canbe formed of an elastomeric polymeric material having a meltingtemperature T_(m) or a degradation temperature greater than 250 degreesCelsius or greater than 300 degrees Celsius such as, for example, asilicone polymer. The protective sheath can be made of other types ofmaterial as long as such a material would not be deformed or melt duringthe thermoforming process or otherwise adversely affect thethermoforming of the upper. In aspects, the protective sheath can applya compressive force to the outer surface of the article beingthermoformed, which can aid in restricting and/or directing the flow ofthe melted first polymeric composition as described herein. Additionallyor alternatively, a vacuum can be drawn on the combination of themolding surface and the article positioned on the molding surface, andoptionally, when present the protective sheath positioned on thearticle. For example, a bag under vacuum can be compressed on theoutside of the article or protective sheath to apply a compressive forceto the article or the article and the protective sheath to ensure thearticle is in flush contact with the molding surface, or is in flushcontact with the molding surface and the protective sheath.Additionally, a protective sheath or a vacuum bag can be used to form atexture on the reflowed first polymeric composition during thethermoforming process.

As discussed above, the thermoforming process includes increasing thetemperature of the first polymeric composition, e.g., the film, fiber,filament, yarn, textile, to a temperature that can cause at least aportion of the first polymeric composition as described herein presentto melt and flow, or to deform. Further, the thermoforming processincludes the subsequent decreasing of the temperature of the firstpolymeric composition to solidify the re-flowed first polymericcomposition as described herein into the desired conformation and/orshape, such as an article of footwear.

As discussed above, it is desirable that the thermoforming process doesnot deform or alter the shaped components, textiles, fibers and/or yarncomprising the second polymeric composition with a deformationtemperature greater than the melting temperature of the first polymericcomposition present in the film, fiber, filament or yarn. In one or moreaspects, the thermoforming can increase the temperature of the un-maskedmaterials, or only the first polymeric composition, to a temperature offrom about 90 degrees Celsius to about 240 degrees Celsius. In aspects,the thermoforming can increase the temperature of the un-maskedmaterials, or only the first polymeric composition, to a temperature offrom about 90 degrees Celsius to about 200 degrees Celsius. In oneaspect, the thermoforming can increase the temperature of the un-maskedmaterials, or only the first polymeric composition, to a temperature offrom about 110 degrees Celsius to about 180 degrees Celsius.

In certain aspects, the temperature of the un-masked materials, or onlythe first polymeric composition, can be increased for about 10 secondsto about 5 minutes. In aspects, the temperature of the un-maskedmaterials, or only the first polymeric composition, can be increased forabout 30 seconds to about 5 minutes. In one aspect, the temperature ofthe un-masked materials, or only the first polymeric composition, can beincreased for about 30 seconds to about 3 minutes.

In certain aspects, the thermoforming can expose the materials on themold surface to a pressure of about 50 kPa to about 300 kPa. In aspects,the thermoforming can expose the materials on the mold surface to apressure of about 50 kPa to about 250 kPa. In one aspect, thethermoforming can expose the materials on the mold surface to a pressureof about from about 100 kPa to about 300 kPa.

In certain aspects, the un-masked materials, or only the first polymericcomposition, can be exposed the thermoforming under the above conditionsmultiple times in a row prior to undergoing the cooling step. Forexample, in some aspects, the un-masked materials, or only the firstpolymeric composition, can be exposed to the temperatures describedabove under the above conditions 2 to 10 times in a row prior toundergoing the cooling step. In an alternative example, in some aspects,the un-masked materials, or only the first polymeric composition, can beexposed the temperatures described above under the above conditionstwice in a row prior to undergoing the cooling step.

In various aspects, subsequent to increasing the temperature ofun-masked materials or only the first polymeric composition, thetemperature of the un-masked materials, or only the first polymericcomposition is decreased to a temperature below the melting temperatureT_(m) of the first polymeric composition present in the film, fiber,filament or yarn as described herein for a duration of time sufficientfor the yarner-flowed first polymeric composition to solidify. Forexample, the un-masked materials or only the first polymeric compositioncan be heated using a thermal energy source, including, but not limitedto, conventional heaters, such as convection heating, a conventionaloven, air-circulating oven or forced hot air oven, steam, targetedmicrowave heat, ultraviolet radiation, infrared heating, andcombinations of any of the foregoing. In an aspect, heat can be appliedusing hotplates, heat presses, or high tonnage presses with rigidclamshell molds. The thermal energy source can further comprise aplurality of thermal energy sources such as a plurality of similarsources, e.g., a plurality of heating coils or infrared emitters.Alternatively, a plurality of thermal energy sources can comprise aplurality of one or more different thermal energy sources, e.g., aplurality of heating coils and a plurality of infrared emitters that canbe used simultaneously or sequentially, or alternatively, used in a modewhere only one of the plurality of thermal energy sources is used at anygiven time.

In some aspects, heating can be carried out such that heat istransferred from another material or object to the un-masked materialsor only the first polymeric composition. For example, a molding surface,such as plate, a multi-part closed mold, or a last, can itself be heateddirectly, e.g., via configuration as a resistive heating element. In analternative aspect, a molding surface, such as a last, can be preheatedto the desired temperature immediately prior to positioning an upper, atextile or an article thereon. In the foregoing aspects, the moldingsurface itself can act as a heating zone that transfers heat to anentire upper.

In some aspects, heating can be carried out using radio-frequencyheating, e.g., microwave radiation, such that the radio-frequency heatsthe compositions via interaction of a radio-frequency field with acomposition, such as the first polymeric composition, that is part offilm, fiber, filament, yarn, textile or article.

In certain aspects, subsequent to heating the un-masked materials, theun-masked materials are cooled to a temperature below the meltingtemperature T_(m) of the first polymeric composition present in the,fiber, filament or yarn as described herein. In such aspects, theun-masked materials can be exposed to reduced temperatures in a coolingzone. The cooling zone can expose the materials to a pressure of about 0kilopascals. The materials, when in the cooling zone, can be exposed toa temperature of about −25 degrees Celsius to about 25 degrees Celsius.In aspects, the materials, when in the cooling zone, can be exposed to atemperature of about −10 degrees Celsius to about 25 degrees Celsius. Inone aspect, the materials, when in the cooling zone, can be exposed to atemperature of about from about −10 degrees Celsius to about 10 degreesCelsius. The materials can be exposed to one or more of the cooling zonetemperatures or ranges discussed above for about 10 seconds to about 5minutes. The materials can be exposed to one or more of the cooling zonetemperatures or ranges discussed above for about 10 seconds to about 3minutes. The materials can be exposed to one or more of the cooling zonetemperatures or ranges discussed above for about 10 seconds to about 2.5minutes.

The textile can be prepared in a number of different ways. In oneaspect, the textile can be prepared as a large piece (e.g., as a rolledgood) from which one or more pieces of are cut out. In another aspect,the textile can be formed into a single piece (e.g., knit into a singleelement having roughly the desired size and shape).

In one aspect, the textile (e.g., a large piece ora single element) canbe thermoformed before cutting out smaller pieces from a larger piece,or before trimming a single element. In another aspect, the textile canbe cut or trimmed (e.g., cutting a large piece into a smaller piece, ortrimming excess material from a single element) and then thermoformed.

In one aspect, the textile (e.g., a cut piece or a single element) canbe attached to a second component (e.g., by stitching) before it isthermoformed. In another aspect, the textile (e.g., a cut piece or asingle element) can be thermoformed after it has been attached to asecond component.

In one aspect, the textile (e.g., an unattached cut piece or singleelement, or a cut piece or single element attached to a secondcomponent) can be thermoformed flat. In another aspect—athree-dimensional conformation can be imparted to the textile (e.g., bystitching or welding it to itself or a second component so that thetextile takes on a curved shape, such as the shape of an upper of anarticle of footwear) before the textile is thermoformed.

In one aspect, the textile can be thermoformed in contact with a moldingsurface (e.g., to impart a curved surface or a surface texture). Themolding surface can be flat, or can have a three-dimensional shape, suchas a last for an article of footwear. In another aspect, the textile canbe supported only at a few points of contact (e.g., supported by a fewpins on a jig) when thermoformed.

In one aspect, the textile can be pressed against the molding surfacewith a force greater than atmospheric pressure during the thermoformingprocess. In another aspect, no additional pressure beyond atmosphericpressure may be applied to the textile during the thermoforming process.

In one aspect, the temperature of the entire textile can be increasedduring the thermoforming process (e.g., the entire textile can beheated). In another aspect, the temperature of only particular regionsof the textile may be increased during the thermoforming process (e.g.,by applying heat to only those regions of the textile, or by maskingother regions of the textile with an insulating material such assilicone).

Films, Fibers, Filaments and Yarns

As discussed above, textiles and shaped components can include theselective incorporation of films, fibers, filaments, and yarns asdescribed alone or in combination with other materials (e.g., secondfilms, fibers, filaments, or yarns that do not fall under the films,fibers, filaments, and yarns described herein). In one aspect, thefilms, fibers and filaments, described herein can be used to form yarnswhich in turn can be used to form textiles, including knit, woven,crocheted, or braided textiles, in accordance with the presentdisclosure. The films, fibers, filaments, and yarns described herein canalso be used to form non-woven textiles in accordance with the presentdisclosure. In one aspect, when the textile is a non-woven textile, thefirst network of yarns includes entangled or bonded yarns comprising thefirst coated yarn. In another aspect, the entangled or bonded yarns canbe mechanically entangled yarns, thermally bonded yarns, yarns bonded bya solvent treatment, chemically bonded yarns, or any combinationthereof.

In certain aspects, one or more of the yarns described herein can bemono-filament yarns or multi-filament yarns. In certain aspects, theyarns can be spun yarns. In various aspects, one or more of the yarnscan be formed using conventional techniques including, but not limitedto, melt-spinning, solution spinning, or electrospinning.

In certain aspects, the fibers described herein can be fibers of varyingsizes, including fibers that are not suitable for spinning into spinninginto commercial yarns. The yarns described herein include yarns that aresuitable for use in a commercial knitting machine as well as yarns thatare not individually suitable for use in a commercial knitting machine.In one aspect, the core yarns described herein have a linear massdensity of about 150 denier to about 1,500 denier, or of about 150denier to about 1,000 denier, or about 250 denier to about 1,500 denier,or about 250 denier to about 1,000 denier, or about 500 to about 1,000denier, or about 500 to about 750 denier, or about 750 to about 1,000denier. In another aspect, the core yarn has a diameter of from about 60micrometers to about 200 micrometers, or about 80 micrometers to about150 micrometers, or about 90 micrometers to about 120 micrometers.

In certain aspects, the yarns and/or fibers described herein can be usedto provide a specific functionality. For example in certain aspects, ayarn as described herein can be thermoformed to form a film havingwater-proof or water-resistant properties.

In one aspect, coated yarns described herein can have a break strengthof from about 0.6 to about 0.9 kilograms of applied force, or of fromabout 0.7 to about 0.9 kilograms of applied force, or of about 0.8 toabout 0.9 kilograms of applied force, or greater than 0.9 kilograms ofapplied force.

As discussed above, in certain aspects, the films, fibers, filaments andyarns described herein can be dyed, e.g., for aesthetic purposes. Invarious aspects, the films, fibers, filaments and yarns can be dyedusing conventional dyeing techniques, such as package dyeing or solutiondyeing. Generally, package dyeing is a process that is performed onalready formed films, fibers, filaments, and yarns, while solutiondyeing adds coloration the thermoplastic polymeric composition prior toforming the films, fibers, filaments, or yarn. In certain aspects, thefilms, fibers, filaments and yarns as described herein are not pigmentedor dyed, which can result in the region comprising the first polymericcomposition being clear or nearly transparent.

In an aspect, the yarns described herein can be produced from films,fibers, or filaments composed of only a single thermoplastic elastomer.In other aspects, the fibers can be composed of a blend of two or moredifferent thermoplastic elastomers.

In one aspect, the yarn is a coated yarn, wherein a core yarn comprisesa second polymeric composition and a coating layer disposed on the coreyarn, the coating layer comprising the first polymeric composition,wherein the first polymeric composition has a first melting temperature.In one aspect, the second polymeric composition is a secondthermoplastic composition having a second deformation temperature, andthe second deformation temperature is at least 20 degrees Celsiusgreater, at least 50 degrees Celsius greater, at least 75 degreesCelsius greater, or at least 100 degrees Celsius greater than the firstmelting temperature of the first polymeric composition. In anotheraspect, the second polymeric composition is a second thermoplasticcomposition having a second melting or deformation temperature, and thesecond deformation temperature is at about 20 degrees Celsius greater,about 50 degrees Celsius greater, about 75 degrees Celsius greater, orabout 100 degrees Celsius greater than the first melting temperature ofthe first polymeric composition.

In one aspect, the first polymeric composition includes a polymericcomponent. In one aspect, the first polymeric composition can include asingle polymeric component (e.g., a single thermoplastic elastomer). Inother aspects, the first polymeric composition can include two orpolymeric components (e.g., two or more different thermoplasticelastomers).

In one aspect, the second polymeric composition is a first thermosetcomposition. In one aspect, the second polymeric composition comprises asecond thermoset composition. The core yarn can be any material whichretains its strength at the temperature at which the first polymericmaterial is extruded during the coating process. The core yarn can benatural fibers or regenerated fibers or filaments, or synthetic fibersor filaments. In one aspect, the core yarn can be composed of a cotton,silk, wool, rayon, nylon, elastane, polyester, polyamide, polyurethane,or polyolefin. In one aspect, the core yarn is composed of polyethyleneterephthalate (PET). In one aspect, the second polymeric composition hasa deformation temperature greater than 200 degrees Celsius, greater than220 degrees Celsius, greater than 240 degrees Celsius, or between about200 degrees Celsius to about 300 degrees Celsius.

In one aspect, the core yarn is a staple yarn, a multi-filament yarn ora mono-filament yarn. In one aspect the core yarn is polytwisted. In oneaspect, the core yarn has a linear density of about 100 denier to about300 denier, or of about 100 to about 250 denier, or about 100 to about200 denier, or about 100 to 150 denier, or about 150 to 300 denier, orabout 200 to 300 denier, or about 250 to 300 denier. In one aspect, thecore yarn has a thickness of about 60 microns to 200 microns, about 60to 160 microns, about 60 to 120 microns, about 60 to 100 microns, about100 to 200 microns, or about 140 to 200 microns.

In one aspect, the core yarn is polyethylene terephthalate having athickness of about 100 denier to about 200 denier, about 125 denier toabout 175 denier, or about 150 denier to 160 denier. In one aspect, thecore yarn is polyethylene terephthalate having a percent elongation ofabout 20 percent to about 30 percent, about 22 percent to about 30percent, about 24 percent to about 30 percent, about 20 percent to about28 percent, or about 20 percent to about 26 percent. In one aspect, thecore yarn is polyethylene terephthalate having a tenacity of about 1gram per denier to about 10 grams per denier, about 3 grams to about 10grams per denier, about 5 grams to about 10 grams per denier, about 1gram to about 7 grams per denier, or about 1 gram to about 5 grams perdenier.

In one aspect, the coated yarn can be produced by extruding the coating(i.e., the first polymeric composition) onto the core yarn through anannular die or orifice such that the coating layer is axially centeredsurrounding the core yarn. The thickness of the coating applied to thecore yarn can vary depending upon the application of the yarn. In oneaspect, the coated yarn is used to produce a knitted textile. In oneaspect, the coated yarn has a nominal average outer diameter of up to1.00 millimeter, or of up to about 0.75 millimeters, or of up to about0.5 millimeters, or of up to about 0.25 millimeters, or of up to about0.2 millimeters, or of up to about 0.1 millimeters. In another aspect,the coating has a nominal average outer diameter of about 0.1millimeters to about 1.00 millimeter, or about 0.1 millimeters to about0.80 millimeters, or about 0.1 millimeters to about 0.60 millimeters. Inanother aspect, the coating on the yarn has an average radial coatingthickness of about 50 micrometers to about 200 micrometers, or about 50micrometers to about 150 micrometers, or about 50 micrometers to about125 micrometers.

In one aspect, the core yarn has a thickness of about 100 denier toabout 200 denier, about 125 denier to about 175 denier, or about 150denier to 160 denier, and the coating has a nominal average outerdiameter of about 0.10 millimeters to about 0.50 millimeters, or ofabout 0.10 millimeters to about 0.25 millimeters, or of about 0.10millimeters to about 0.20 millimeters. In one aspect, the core yarn ispolyethylene terephthalate having a thickness of about 100 denier toabout 200 denier, about 125 denier to about 175 denier, or about 150denier to about 160 denier, and the coating has a nominal average outerdiameter of about 0.10 millimeters to about 0.50 millimeters, or ofabout 0.10 millimeters to about 0.25 millimeters, or of about 0.10millimeters to about 0.20 millimeters.

In a further aspect, the coated yarn has a net total diameter of fromabout 0.2 to about 0.6 millimeters, or about 0.3 to about 0.5millimeters, or about 0.4 to about 0.6 millimeters In some aspects, alubricating oil including, but not limited to, mineral oil or siliconeoil can be present on the yarn at from about 0.5 percent to about 2percent by weight, or from about 0.5 percent to about 1.5 percent byweight, or from about 0.5 percent to about 1 percent by weight. In someaspects, lubricating compositions can be applied to the surface of thecoated yarn before or during the process of forming the textile. In someaspects, the thermoplastic composition and the lubricating compositionare miscible when the thermoplastic composition is reflowed andresolidified in the presence of the lubricating composition. Followingreflowing and resolidification, the reflowed and resolidifiedcomposition can comprise the lubricating composition.

In one aspect, the core yarn has a percent elongation of about 8 percentto about 30 percent, about 10 percent to about 30 percent, about 15percent to about 30 percent, about 20 percent to about 30 percent, about10 percent to about 25 percent, or about 10 percent to about 20 percent.In one aspect, the core yarn has a tenacity of about 1 gram per denierto about 10 grams per denier, about 2 grams per denier to about 8 gramsper denier, about 4 grams per denier to about 8 grams per denier, orabout 2 grams per denier to about 6 grams per denier.

In another aspect, the yarn can be used as an inlaid that isincorporated into a textile (e.g., knit, woven etc.). In one aspect, thecore yarn has a thickness of about 200 denier to about 300 denier, about225 denier to about 275 denier, or about 250 denier to 260 denier. Inone aspect, the core yarn is polyethylene terephthalate having athickness of about 200 denier to about 300 denier, about 225 denier toabout 275 denier, or about 250 denier to 260 denier. In one aspect, thecoating has a nominal average outer diameter of up to about 3.0millimeters, of up to about 2.5 millimeters, of up to about 2millimeters, of up to about 1.5 millimeters, of up to about 1.0millimeter, or of up to about 0.5 millimeters. In one aspect, the coreyarn has a thickness of about 200 denier to about 300 denier, about 225denier to about 275 denier, or about 250 denier to about 260 denier, andthe coating has a nominal average outer diameter of about 0.5millimeters to about 3.0 millimeters, or of about 1.0 millimeter toabout 2.5 millimeters, or of about 1.5 millimeters to about 2.0millimeters. In one aspect, the core yarn is polyethylene terephthalatehaving a thickness of about 200 denier to about 300 denier, about 225denier to about 275 denier, or about 250 denier to about 260 denier, andthe coating has a nominal average outer diameter of about 0.5millimeters to about 3.0 millimeters , or of about 1.0 millimeter toabout 2.5 millimeters, or of about 1.5 millimeters to about 2.0millimeters.

The films, fibers, filaments, and yarns described herein have severalunique properties that make them suitable for the production of articlessuch as textiles and the like. In one aspect, the films, fibers,filaments, and yards have improved resistance to abrasion. In otheraspects, textiles and articles produced from or incorporating the films,fibers, filaments, and yarns described herein have improved resistanceto abrasion. For example, when the films, fibers, filaments, and yarnsare used to produce the outer sole of an article of footwear, the outersole will have improved durability as the outer sole is less likely tolose mass over time.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, yarn, and textile has an Akron abrasion of lessthan 0.50 cubic centimeters, optionally less than 0.40 cubiccentimeters, less than 0.30 cubic centimeters, less than 0.20 cubiccentimeters, or less than 0.10 cubic centimeters as determined using theAkron Abrasion Test. In another aspect, when thermoformed, the firstpolymeric composition of the film, fibers, filaments, yarn, and textilehas an Akron abrasion of about 0.05 cubic centimeters to about 0.5 cubiccentimeters, about 0.10 cubic centimeters to about 0.45 cubiccentimeters, or about 0.05 to about 0.20 cubic centimeters as determinedusing the Akron Abrasion Test.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, yarn, and textile has an Akron abrasion of lessthan 500 milligrams, optionally less than 400 milligrams, less than 300milligrams, less than 200 milligrams, or less than 100 milligrams asdetermined using the Akron Abrasion Test. In another aspect, whenthermoformed, the first polymeric composition of the film, fibers,filaments, yarn, and textile has an Akron abrasion of about 50milligrams to about 500 milligrams, about 100 milligrams to about 400milligrams, or about 100 milligrams to about 150 milligrams asdetermined using the Akron Abrasion Test.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, yarn, and textile has a DIN abrasion of lessthan 0.30 cubic centimeters, optionally less than 0.20 cubiccentimeters, less than 0.10 cubic centimeters, less than 0.05 cubiccentimeters, or less than 0.07 cubic centimeters as determined using theDIN Abrasion Test. In another aspect, when thermoformed, the firstpolymeric composition of the film, fibers, filaments, yarn, and textilehas a DIN abrasion of about 0.01 cubic centimeters to about 0.30 cubiccentimeters, about 0.05 cubic centimeters to about 0.20 cubiccentimeters, or about 0.05 cubic centimeters to about 0.10 cubiccentimeters as determined using the DIN Abrasion Test.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, and yarn has a DIN abrasion of less than 300milligrams, optionally less than 200 milligrams, less than 100milligrams, less than 50 milligrams, or less than 30 milligrams asdetermined using the DIN Abrasion Test. In another aspect, whenthermoformed, the first polymeric composition of the film, fibers,filaments, yarn, and textile has a DIN abrasion of about 10 milligramsto about 300 milligrams, about 50 milligrams to about 250 milligrams, orabout 50 milligrams to about 100 milligrams as determined using the DINAbrasion Test.

In certain aspects, the films, fibers, and yarns described herein whenincorporated into a textile or article the product has improved tractionproperties. In one aspect, the coefficient of friction of the films,fibers or yarns can be used to measure traction properties on varioussurfaces.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, yarn, and textile has a dry dynamic coefficientof friction (COF) on a dry surface (e.g., a smooth, flat, or texturedsurface such as, for example, wooden parquet court, concrete, asphalt,laminate, brick, or ceramic tile) of greater than 0.6, optionally ofgreater than 0.7, greater than 0.8, greater than 0.9, greater than 1.0,as determined using the Coefficient of Friction Test. In another aspect,when thermoformed, the first polymeric composition of the film, fibers,filaments, yarn, and textile has a dry dynamic COF of greater than 0.15,optionally of greater than 0.2, greater than 0.25, or greater than 0.3,using theCoefficient of Friction Test.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, yarn, and polymeric has a wet dynamic COF ofgreater than 0.25, optionally of greater than 0.30, greater than 0.35,greater than 0.40, or greater than 0.50, as determined using theCoefficient of Friction Test. In another aspect, when thermoformed, thefirst polymeric composition of the film, fibers, filaments, yarn, andtextile has a wet dynamic COF of greater than 0.15, optionally ofgreater than 0.2, greater than 0.25, or greater than 0.3, using theCoefficient of Friction Test.

In certain aspect, it is desirable for the dynamic coefficient offriction for the same dry and wet surface (e.g., smooth concrete orcourt) to be as close as possible. In one aspect, the difference betweenthe dynamic coefficient of friction of the dry surface and the wetsurface is less than 15 percent. In another aspect, the differencebetween the dynamic coefficient of friction of the dry surface and thewet surface is from about 0 percent to about 15 percent, about 1 percentto about 10 percent, about 1 percent to about 5 percent, or about 2percent to about 5 percent.

In one aspect, when thermoformed, the first polymeric composition of thefilm, fibers, filaments, yarn, and textile has a melting temperaturefrom about 100 degrees Celsius to about 210 degrees Celsius, optionallyfrom about 110 degrees Celsius to about 195 degrees Celsius, from about120 degrees Celsius to about 180 degrees Celsius, or from about 120degrees Celsius to about 170 degrees Celsius. I another aspect, thefirst polymeric composition has a melting temperature greater than about120 degrees Celsius and less than about 170 degrees Celsius, andoptionally greater than about 130 degrees Celsius, and less than about160 degrees Celsius.

In a further aspect, when the melting temperature is greater than 100degrees Celsius, the integrity of articles formed from or incorporatingthe first polymeric composition is preserved if the articles brieflyencounter similar temperatures, for example, during shipping or storage.In another aspect, when the melting temperature is greater than 100degrees Celsius, or greater than 120 degrees Celsius, articles formedfrom or incorporating the first polymeric composition can be steamedwithout melting or uncontrollably fusing any polyester componentsincorporated in the articles for purposes such as fill, zonal surface,or comfort features, as well as stretch yarn used for snugness and fitfeatures.

In one aspect, when the melting temperature is greater than 120 degreesCelsius, materials incorporating the first or second polymericcomposition disclosed herein are unlikely to soften and/or become tackyduring use on a hot paved surface, a court surface, an artificial ornatural soccer pitch, or a similar playing surface, track, or field. Inone aspect, the higher the melting temperature of the first or secondpolymeric composition and the greater its enthalpy of melting, thegreater the ability of an article of footwear or athletic equipmentincorporating or constructed from the first or second polymericcomposition to withstand contact heating excursions, frictional surfaceheating events, or environmental heating excursions. In one aspect, suchheat excursions may arise when the articles contact hot ground, court,or turf surfaces, or from frictional heating that comes from rubbing orabrasion when the articles contact another surface such as the ground,another shoe, a ball, or the like.

In another aspect, when the melting temperature is less than about 210degrees Celsius, or less than about 200 degrees Celsius, or less thanabout 190 degrees Celsius, or less than about 180 degrees Celsius, orless than about 175 degrees Celsius, but greater than about 120 degreesCelsius, or greater than about 110 degrees Celsius, or greater thanabout 103 degrees Celsius, polymer coated yarns can be melted for thepurposes of molding and/or thermoforming a given region of textilesknitted therefrom in order to impart desirable design and aestheticfeatures in a short period of time.

In one aspect, a melting temperature lower than 140 degrees Celsius canprevent or mitigate the risk dye migration from polyester yarnsincorporated in the footwear or other articles. In a further aspect, dyemigration from package-dyed polyester yarns or filaments is adiffusion-limited process and short periods of exposure to temperaturesgreater than 140 degrees Celsius, such as during thermoforming, do notextensively damage, discolor, or otherwise render the appearance of thefootwear or other articles unacceptable. However, in another aspect, ifthe melting temperature of the polymer coating is greater than about 210degrees Celsius, thermal damage and dye migration may occur.

In one aspect, a high melting enthalpy indicates a longer heating timeis required to ensure a polymer is fully melted and will flow well. Inanother aspect, a low melting enthalpy requires less heating time toensure full melting and good flow.

In a further aspect, high cooling exotherms indicate rapid transitionsfrom molten to solid. In another aspect, higher recrystallizationtemperatures indicate polymers are capable of solidifying at highertemperatures. In one aspect, high-temperature solidification can bebeneficial for thermoforming. In one aspect, recrystallization above 95degrees Celsius can promote rapid setting after thermoforming, reducecycle time, reduce cooling demands, and improve stability of shoecomponents during assembly and use.

In one aspect, viscosity of the coating compositions disclosed hereincan affect the properties and processing of the coating compositions. Ina further aspect, high viscosities at low shear rates (e.g., less than 1reciprocal second) indicate resistance to flow, displacement, and moresolid-like behavior. In another aspect, low viscosities at higher shearrates (e.g., greater than 10 reciprocal seconds) lend themselves tohigh-speed extrusion. In one aspect, as viscosity increases, the abilityto flow and deform adequately to coat core yarn substrate becomeschallenging. In another aspect, materials that exhibit high shearthinning indices (e.g., where viscosity at 10 or 100 reciprocal secondsis lower than at 1 reciprocal second) can be challenging to extrude andmay melt fracture if coated or extruded at a velocity that is too high.

In one aspect, the first polymeric composition of the film, fibers,filaments, yarn, and textile has a melt flow index of at least 0.2 gramsper 10 minutes, optionally at least 2, at least 5, at least 10, at least15, at least 20, at least 25, at least 30, at least 40, or at least 50grams per 10 minutes, as determined using the Method to Determine theMelt Flow Index (ASTM D1238-13) at 160 degrees Celsius using a weight of2.16 kg. In another aspect, when thermoformed, the first polymericcomposition of the film, fibers, filaments, and yarn has a melt flowindex of at least 0.2 grams per 10 minutes, optionally at least 5 gramsper 10 minutes, at least 10 grams per 10 minutes, at least 15 grams per10 minutes, at least 20 grams per 10 minutes, at least 25 grams per 10minutes, at least 30 grams per 10 minutes, at least 40 grams per 10minutes, or at least 50 grams per 10 minutes, as determined using theMethod to Determine the Melt Flow Index (ASTM D1238-13) at 200 degreesCelsius using a weight of 10 kg. In one aspect, having a suitable meltflow rate or melt flow index allows the first polymeric composition tore-flow adequately around and between the knitted or woven textilefibers as disclosed herein. In another aspect, having a suitable meltflow rate allows a skin-like structure to form when the knitted or woventextile is thermoformed.

In one aspect, the first polymeric composition of the film, fibers,filaments, yarn, and textile has a durometer Shore A hardness of about50 to about 90 Shore A, optionally from about 55 to about 85 Shore A,from about 60 to about 80 Shore A, from about 60 to about 70 Shore A, orfrom about 67 to about 77 shore A.

In one aspect, the first polymeric composition of the film, fibers,filaments, yarn, or textile has a specific gravity from about 0.8 toabout 1.5, optionally from about 0.8 to about 1.30, or from about 0.88to about 1.20. In another aspect, the first polymeric composition of thefilm, fibers, filaments, yarn, or textile has a specific gravity of fromabout 0.80 grams per cubic centimeter to about 1.30 grams per cubiccentimeter, or from about 1.0 grams per cubic centimeter to about 1.2grams per cubic centimeter as determined by the Method to DetermineSpecific Gravity (ASTM D792).

In one aspect, the first polymeric composition of the film, fibers,filaments, yarn, or textile have two or more of the first properties, oroptionally three or more, four or more, five or more, six or more, sevenor more, or all ten first properties provided above.

In one or more aspects, the textile described herein can exhibit amodulus of from about 1 megapascal to about 500 megapascals. In certainaspects, the coated yarns can exhibit a modulus of from about 5megapascals to about 150 megapascals, or of from about 20 megapascals toabout 130 megapascals, or of from about 30 megapascals to about 120megapascals, or of from about 40 megapascals to about 110 megapascals.The term “modulus” as used herein refers to a respective testing methoddescribed below in the Property Analysis And Characterization Proceduressection. In one aspect, a material having a high modulus is relativelystiffer than a material having a low modulus, which is more flexible. Inanother aspect, when the first polymeric compositions are used ascoatings for yarns and incorporated into textiles and articles asdescribed herein, textiles and articles comprising thermoplasticpolymeric compositions having a lower modulus will be more flexible thanarticles comprising thermoplastic polymeric compositions having a highmodulus.

In addition to the first properties, when thermoformed, the firstpolymeric composition of the film, fibers, filaments, yarn, or textilehas one or more second properties. In one aspect, when thermoformed, thefirst polymeric composition of the film, fibers, filaments, yarn, ortextile has a glass transition temperature less than 50 degrees Celsius,optionally less than 30 degrees Celsius, less than 0 degrees Celsius,less than −10 degrees Celsius, less than −20 degrees Celsius, or lessthan −30 degrees Celsius. In one aspect, when thermoformed, the firstpolymeric composition of the film, fibers, filaments, and yarn has astress at break greater than 7 megapascals, optionally greater than 8megapascals, as determined using Method to Determine the Modulus,Tenacity, and Elongation (yarn) at 25 degrees Celsius. In one aspect,when thermoformed, the first polymeric composition of the film, fibers,filaments, and yarn has a tensile stress at 300 percent modulus greaterthan 2 megapascals, optionally greater than 2.5 megapascals, or greaterthan 3 megapascals as determined using Method to Determine the Modulus,Tenacity, and Elongation (yarn) at 25 degrees Celsius. In one aspect,when thermoformed, the first polymeric composition of the film, fibers,filaments, and yarn has an elongation at break greater than 400 percent,optionally greater than 450 percent, optionally greater than 500percent, or greater than 550 percent as determined using Method toDetermine the Modulus, Tenacity, and Elongation (yarn) at 25 degreesCelsius. In another aspect, when thermoformed, the first polymericcomposition of the film, fibers, filaments, and yarn has two or more ofthe second properties, or optionally three or more, or all four secondproperties.

In one aspect, the textiles described herein or articles comprising thetextiles described herein can be subjected to Akron Abrasion testing asdescribed in the Property Analysis and Characterization Procedures. Inone aspect, after 300 cycles of Akron Abrasion testing, the textiles orarticles have a mass loss of from 0 to 0.05 weight percent, optionallyfrom 0 to 0.04 weight percent, or from 0 to 0.03 weight percent, or from0 to 0.02 weight percent after 300 cycles. In another aspect, after 3000cycles of Akron Abrasion testing, the textiles or articles have a massloss of from 0 to 0.2 weight percent, or of from 0 to 0.15 weightpercent, or of from 0 to 0.1 weight percent, or of from 0 to 0.05 weightpercent. In still another aspect, the textiles described herein orarticles comprising the textiles described herein can be subjected toStoll Abrasion testing as described in the Property Analysis andCharacterization Procedures. In one aspect, the articles or textiles donot show significant Stoll Abrasion loss or degradation after at least1600 cycles, or after at least 2000 cycles, or after at least 2500cycles.

In one aspect, the textiles disclosed herein can be subjected to BallyFlex testing as described in the Property Analysis and CharacterizationProcedures. In one aspect, the textiles to not exhibit cracking after atleast 100 cycles in a dry Bally flex test. In another aspect, thetextiles do not exhibit cracking after at least 15,000 cycles in a wetBally flex test.

In another aspect, when the textiles disclosed herein are included ascomponents of an upper for an article of footwear, a textile-ball impacttest or a boot-ball impact test can be performed as described in theProperty Analysis and Characterization Procedures. In one aspect, thetextile or an upper comprising the textile produces a ball spin rate offrom about 220 revolutions per minute to about 240 revolutions perminute, or of about 220 revolutions per minute to about 230 revolutionsper minute. In a further aspect, the revolutions per minute can beright-handed (positive, or clockwise) or left-handed (negative, orcounterclockwise). In one aspect, a higher number of revolutions perminute is desirable for generating a ball path with suitable curvaturefor avoiding opposing players on, for example, a soccer (football)field.

In one aspect, following thermoforming, the first polymeric compositionhas one or more first properties selected from:

-   a) an Akron abrasion of from 0.00 to 0.50 cubic centimeters,    optionally 0.00 to 0.40 cubic centimeters, 0.00 to 0.30 cubic    centimeters, 0.00 to 0.20 cubic centimeters, or 0.00 to 0.10 cubic    centimeters as determined using the Akron Abrasion Test;-   b) a DIN abrasion of from 0.00 to 0.30 cubic centimeters, from 0.00    to 0.20 cubic centimeters, 0.00 to 0.10 cubic centimeters, or 0.00    to 0.05 cubic centimeters, as determined using the DIN Abrasion    Test;-   c) a dry dynamic coefficient of friction (COF) of from 0.5 to 1.0,    optionally of 0.7 to 1.0, 0.8 to 1.0, 0.9 to 1.0, or greater than    1.0, as determined using the Coefficient of Friction Test;-   d) a wet dynamic COF of from 0.25 to 0.50, optionally of 0.30 to    0.50, of 0.35 to 0.50, 0.40 to 0.50, or greater than 0.50, as    determined using the Coefficient of Friction Test;-   e) a dry dynamic COF of 0.15 to 0.3, optionally of 0.2 to 0.3, 0.25    to 0.3, or greater than 0.3, using the Coefficient of Friction Test;-   f) a wet dynamic COF of 0.15 to 0.3, optionally of 0.2 to 0.3, 0.25    to 0.3, or greater than 0.3, using the Coefficient of Friction Test;-   g) a melting temperature from about 100 degrees C. to about 210    degrees C., optionally from about 110 degrees C. to about 195    degrees C., from about 120 degrees C. to about 180 degrees C., or    from about 120 degrees C. to about 170 degrees C.;-   h) a melt flow rate of at least 0.2 grams to at least 50 grams per    10 minutes, optionally at least 2 to at least 50, at least 5 to at    least 50, at least 10 to at least 50, at least 15 to at least 50, at    least 20 to at least 50 to at least 50, at least 25 to at least 50,    at least 30 to at least 50, at least 40 to at least 50, or at least    50 grams per 10 minutes, as determined using ASTM D1238-13 at 160    degrees C. using a weight of 2.16 kg;-   i) a melt flow rate of at least 0.2 grams to at least 50 grams per    10 minutes, optionally at least 2 to at least 50, at least 5 to at    least 50, at least 10 to at least 50, at least 15 to at least 50, at    least 20 to at least 50 to at least 50, at least 25 to at least 50,    at least 30 to at least 50, at least 40 to at least 50, or at least    50 grams per 10 minutes, as determined using ASTM D1238-13 at 200    degrees C. using a weight of 10 kg;-   j) a durometer from about 50 to about 90 Shore A, optionally from    about 55 to about 85 Shore A, from about 60 to about 80 Shore A, or    from about 60 to about 70 Shore A;-   k) a glass transition temperature of from −10 degrees Celsius to 50    degrees Celsius, optionally from −10 degrees Celsius to 30 degrees    Celsius, or from −10 degrees Celsius to 20 degrees Celsius, or from    −10 degrees Celsius to 10 degrees Celsius;-   l) a specific gravity from about 0.8 to about 1.5, optionally from    about 0.85 to about 1.30, or from about 0.88 to about 1.20;-   m) a mass loss of less than 0.05 weight percent after 300 cycles,    optionally from about 0.01 weight percent to about 0.05 weight    percent after 300 cycles;-   n) a mass loss of less than 0.20 weight percent after 3,000 cycles,    optionally from about 0.01 weight percent to about 0.20 weight    percent, about 0.1 weight percent to about 0.20 weight percent, or    about 0.5 weight percent to about 0.20 weight percent after 3,000    cycles;-   o) a Stoll abrasion resistance of at least 1,600 cycles, or about    1,600 cycle to about 2,500 cycles;-   p) a Bally Flex of at least 100 cycles, or from about 100 cycles to    about 1,000 cycles; and-   q) a wet Bally Flex of at least 5,000 cycles, or from about 5,000    cycles to about 20,000 cycles.

In one aspect, following thermoforming, knitted or woven textilescomprising the first polymer composition possesses desirable performanceproperties. In a further aspect, the disclosed thermoformed knitted orwoven textiles outperform traditional materials included in uppers forarticles of footwear such as Kangaroo leather and Duragon skin (a tradename referring to a preformed, polyurethane laminated skin on apolyester textile). For example, the thermoformed knit textiles showedsimilar dry and wet coefficients of friction (e.g., boot-to-ballinteraction) as the laminated Duragon skin; however, the knitted textileas described herein can be produced in a streamlined, more integrated,lower waste manner of construction. In other aspects, the thermoformedtextiles and/or footwear uppers containing the coated yarns disclosedherein exhibit higher wet and dry COF values overall, and a lower degreeof difference between dry COF and wet COF than DURAGON skin. In otheraspects, following thermoforming, the first polymeric composition hasone or more properties selected from:

-   a) a stress at break of at least 7 megapascals to 8 megapascals,    optionally greater than 8 megapascals, as determined using Method to    Determine the Modulus (plaque) at 25 degrees Celsius;-   b) a tensile stress at 300 percent modulus of at least 2 megapascals    to 3 megapascals, optionally 2.5 megapascals to 3 megapascals, or    greater than 3 megapascals as determined using Method to Determine    the Modulus (plaque) at 25 degrees Celsius;-   c) an elongation at break of at least 450 percent to 550 percent,    optionally from 500 percent to 550 percent, or greater than 550    percent as determined using Method to Determine the Modulus (plaque)    at 25 degrees C.;-   d) a difference between the dry dynamic coefficient of friction and    the dry static coefficient of friction of from 0 to 20 percent as    determined by the Method for Determining Coefficient of Friction    described in the Property Analysis and Characterization Procedures;-   e) a difference between the wet dynamic coefficient of friction and    the wet static coefficient of friction of from 0 to 20 percent as    determined by the Method for Determining Coefficient of Friction    described in the Property Analysis and Characterization Procedures;    and-   f) a difference between the wet static coefficient of friction and    the dry static coefficient of friction of from 0 to 20 percent as    determined by the Method for Determining Coefficient of Friction    described in the Property Analysis and Characterization Procedures.

In certain aspects, the films, fibers, and yarns described herein canexhibit a tenacity greater than 1 gram/denier. In one aspect, the films,fibers, and yarns described herein can exhibit a tenacity of from about1 gram/denier to about 5 grams/denier. In one or more aspects, thefilms, fibers, and yarns described herein can exhibit a tenacity of fromabout 1.5 grams/denier to about 4.5 grams/denier. In one aspect, thefilms, fibers, and yarns described herein can exhibit a tenacity of fromabout 2 grams/denier to about 4.5 grams/denier. “Tenacity” as usedherein refers to a property of a fiber or yarn, and is determined usingthe respective testing method and sampling procedure described below inthe Property Analysis and Characterization Procedures section.

In certain aspects, it can be desired to utilize a yarn that is suitablefor use on commercial knitting equipment. A free-standing shrinkage of ayarn at 50 degrees Celsius is one property that can be predictive of asuitable yarn for use on a commercial knitting machine. In certainaspects, a films, fibers, filaments, and yarns described herein canexhibit a free-standing shrinkage when heated from 20 degrees Celsius to70 degrees Celsius of less than 15 percent. In various aspects, thefilms, fibers, and yarns described herein can exhibit free-standingshrinkage when heated from 20 degrees Celsius to 70 degrees Celsius ofabout 0 percent to about 60 percent, about 0 percent to about 30percent, or about 0 percent to about 15 percent. The term “free-standingshrinkage” as used herein refers to a property of a yarn and arespective testing method described below in the Property Analysis andCharacterization Procedures section.

In one or more aspects, the free-standing shrinkage of a yarn at 70degrees Celsius can be a useful indicator of the ability of a yarn to beexposed to certain environmental conditions without any substantialchanges to the physical structure of the yarn. In certain aspects, ayarn comprising the low processing temperature polymeric composition canexhibit a free-standing shrinkage when heated from 20 degrees Celsius to70 degrees Celsius of from about 0% to about 60%. In one or moreaspects, a yarn comprising the low processing temperature polymericcomposition can exhibit a free-standing shrinkage when heated from 20degrees Celsius to 70 degrees Celsius of from about 0% to about 30%. Inone aspect, a yarn comprising the low processing temperature polymericcomposition can exhibit a free-standing shrinkage when heated from 20degrees Celsius to 70 degrees Celsius of from about 0% to about 20%.

As discussed above, in certain aspects, the first polymeric compositionas described herein and the second polymeric composition have differingproperties. In various aspects, these differing properties allow for thecoated fibers as described herein, during a thermoforming process, tomelt and flow, and subsequently cool and solidify into a differentstructure than that prior to the thermoforming process (e.g., thermoformfrom a yarn to a melted yarn component), while the an uncoated fibercannot deform or melt during such a process and can maintain itsstructure (e.g., as a yarn), when the thermoforming process is conductedat a temperature below the melting temperature of the uncoated fibers.In such aspects, the melted yarn component formed from the coated fibersas described herein during the thermoforming process can be integrallyconnected to the non-altered structure (e.g., a yarn or fiber), whichcan provide three-dimensional structure and/or other properties targetedto specific spots on an article of wear.

Exemplary Thermoplastic Elastomers

In various aspects, the polymeric compositions described herein compriseone or more thermoplastic elastomers. In an aspect, an “elastomer” canbe defined as a material having an elongation at break greater than 400percent as determined using ASTM D-412-98 at 25 degrees Celsius. Inanother aspect, the elastomer can be formed into a plaque, wherein theplaque has a break strength of from 10 to 35 kilogram-force (kgf), or offrom about 10 to about 25 kilogram-force, or of from about 10 to about20 kilogram-force, or of from about 15 to about 35 kilogram-force, or offrom about 20 to about 30 kilogram-force. In another aspect, tensilebreaking strength or ultimate strength, if adjusted for cross-sectionalarea, can be greater than 70 kilogram·force per square centimeter, orgreater than 80 kilogram·force per square centimeter. In another aspect,the elastomer plaque can have a strain to break of from 450 percent to800 percent, or from 500 to 800 percent, or from 500 to 750 percent, orfrom 600 to 750 percent, or from 450 to 700 percent. In still anotheraspect, the elastomer plaque can have a load at 100 percent strain offrom 3 to 8 kilogram-force per millimeter, or of about 3 to about 7kilogram-force per millimeter, about 3.5 to about 6.5 kilogram-force permillimeter, or about 4 to about 5 kilogram-force per millimeter. In oneaspect, the elastomer plaque can have a toughness of from 850kilogram·millimeters to 2200 kilogram·millimeters, or of from about 850kilogram·millimeters to about 2000 kilogram·millimeters, or of fromabout 900 kilogram·millimeters to about 1750 kilogram·millimeters, or offrom about 1000 kilogram·millimeters to about 1500 kilogram·millimeters,or of from about 1500 kilogram·millimeters to about 2000kilogram·millimeters. In an aspect, the elastomer plaque can have astiffness of from about 35 to about 155, or of from about 50 to about150, or of from about 50 to about 100, or of from about 50 to about 75,or of from about 60 to about 155, or of from about 80 to about 150. Instill another aspect, the elastomer plaque can have a tear strength offrom about 35 to about 80, or of from about 35 to about 75, or of fromabout 40 to about 60, or of from about 45 to about 50.

In aspects, exemplary thermoplastic elastomers include homo-polymers andco-polymers. The term “polymer” refers to a polymerized molecule havingone or more monomer species, and includes homopolymers and copolymers.The term “copolymer” refers to a polymer having two or more monomerspecies, and includes terpolymers (i.e., copolymers having three monomerspecies). In certain aspects, the thermoplastic elastomer can be arandom co-polymer. In one aspect, the thermoplastic elastomer can be ablock co-polymer. For example, the thermoplastic elastomer can be ablock co-polymer having repeating blocks of polymeric units of the samechemical structure (segments) which are relatively harder (hardsegments), and repeating blocks of polymeric segments which arerelatively softer (soft segments). In various aspects, in blockco-polymers, including block co-polymers having repeating hard segmentsand soft segments, physical crosslinks can be present within the blocksor between the blocks or both within and between the blocks. Particularexamples of hard segments include isocyanate segments and polyamidesegments. Particular examples of soft segments include polyethersegments and polyester segments. As used herein, the polymeric segmentcan be referred to as being a particular type of polymeric segment suchas, for example, an isocyanate segment, a polyamide segment, a polyethersegment, a polyester segment, and the like. It is understood that thechemical structure of the segment is derived from the described chemicalstructure. For example, an isocyanate segment is a polymerized unitincluding an isocyanate functional group. When referring to a block ofpolymeric segments of a particular chemical structure, the block cancontain up to 10 mol percent of segments of other chemical structures.For example, as used herein, a polyether segment is understood toinclude up to 10 mol percent of non-polyether segments.

In one aspect, the first polymeric composition comprises a polymericcomponent consisting of all the polymers present in the polymericcomposition; optionally wherein and the polymeric component comprisestwo or more polymers, wherein the two or more polymers differ from eachother in chemical structure of individual segments of each of the two ormore polymers, or in molecular weight of each of the two or morepolymers, or in both.

In various aspects, the thermoplastic elastomer can include one or moreof a thermoplastic copolyester elastomer, a thermoplastic polyetherblock amide elastomer, a thermoplastic polyurethane elastomer, apolyolefin based-copolymer elastomer, a thermoplastic styrenic copolymerelastomer, a thermoplastic ionomer elastomer, or any combinationthereof. In one aspect, the first polymeric composition comprises athermoplastic elastomeric styrenic copolymer. In a further aspect, thethermoplastic elastomeric styrenic copolymer can be a styrene butadienestyrene (SBS) block copolymer, a styrene ethylene/butylene styrene(SEBS) resin, a styrene acrylonitrile (SAN) resin, or any combinationthereof. In one aspect, the first polymeric composition comprises athermoplastic elastomeric polyester polyurethane, a thermoplasticpolyether polyurethane, or any combination thereof. In some aspects, thethermoplastic elastomeric polyester polyurethane can be an aromaticpolyester, an aliphatic composition, or a combination thereof. It shouldbe understood that other thermoplastic polymeric materials notspecifically described below are also contemplated for use in the coatedfiber as described herein and/or the an uncoated fiber. In one aspect,the first polymeric composition comprising the thermoplastic elastomerhas a melting temperature greater than about 110 degrees Celsius andless than about 170 degrees Celsius. In another aspect, the firstpolymeric composition comprising the thermoplastic elastomer has amelting temperature of about 110 degrees Celsius to about 170 degreesCelsius, about 115 degrees Celsius to about 160 degrees Celsius, about120 degrees Celsius to about 150 degrees Celsius, about 125 degreesCelsius to about 140 degrees Celsius, about 110 degrees Celsius to about150 degrees Celsius, or about 110 degrees Celsius to about 125 degreesCelsius.

In various aspects, the thermoplastic elastomer has a glass transitiontemperature (T_(g)) less than 50 degrees Celsius when determined inaccordance with ASTM D3418-97 as described herein below. In someaspects, the thermoplastic elastomer has a glass transition temperature(T_(g)) of about −60 degrees Celsius to about 50 degrees Celsius, about−25 degrees Celsius to about 40 degrees Celsius, about −20 degreesCelsius to about 30 degrees Celsius, about −20 degrees Celsius to about20 degrees Celsius, or of about −10 degrees Celsius to about 10 degreesCelsius, when determined in accordance with ASTM D3418-97 as describedherein below. In one aspect, the glass transition temperature of thethermoplastic elastomer is selected such that articles incorporating thecoated yarns disclosed herein, wherein the coated yarns comprise acoating material comprising the thermoplastic elastomer, thethermoplastic material is above its glass transition temperature duringnormal wear when incorporated into an article of footwear (i.e., is morerubbery and less brittle).

In one aspect, the thermoplastic elastomer comprises: (a) a plurality offirst segments; (b) a plurality of second segments; and, optionally, (c)a plurality of third segments. In various aspects, the thermoplasticelastomer is a block copolymer. In some aspects, the thermoplasticelastomer is a segmented copolymer. In further aspects, thethermoplastic elastomer is a random copolymer. In still further aspects,the thermoplastic elastomer is a condensation copolymer.

In a further aspect, the thermoplastic elastomer can have a weightaverage molecular weight of about 50,000 Daltons to about 1,000,000Daltons; about 50,000 Daltons to about 500,000 Daltons; about 75,000Daltons to about 300,000 Daltons; about 100,000 Daltons to about 200,000Daltons.

In a further aspect, the thermoplastic elastomer can have a ratio offirst segments to second segments from about 1:1 to about 1:2 based onthe weight of each of the first segments and the second segments; or ofabout 1:1 to about 1:1.5 based on the weight of each of the firstsegments and the second segments.

In a further aspect, the thermoplastic elastomer can have a ratio offirst segments to third segments from about 1:1 to about 1:5 based onthe weight of each of the first segments and the third segments; about1:1 to about 1:3 based on the weight of each of the first segments andthe third segments; about 1:1 to about 1:2 based on the weight of eachof the first segments and the third segments; about 1:1 to about 1:3based on the weight of each of the first segments and the thirdsegments.

In a further aspect, the thermoplastic elastomer can have first segmentsderived from a first component having a number-average molecular weightof about 250 Daltons to about 6000 Daltons; about 400 Daltons to about6,000 Daltons; about 350 Daltons to about 5,000 Daltons; or about 500Daltons to about 3,000 Daltons.

In some aspects, the thermoplastic elastomer can comprise phaseseparated domains. For example, a plurality of first segments canphase-separate into domains comprising primarily the first segments.Moreover, a plurality of second segments derived from segments having adifferent chemical structure can phase-separate into domains comprisingprimarily the second segments. In some aspects, the first segments cancomprise hard segments, and the second segments can comprise softsegments. In other aspects, the thermoplastic elastomer can comprisephase-separated domains comprising a plurality of first copolyesterunits.

In one aspect, prior to thermoforming, the first polymeric compositionhas a glass transition temperature glass transition temperature of fromabout 20 degrees Celsius to about −60 degrees Celsius. In one aspect,prior to thermoforming, the first polymeric composition has a TaberAbrasion Resistance of from about 10 milligrams to about 40 milligramsas determined by ASTM D3389. In one aspect, prior to thermoforming, thefirst polymeric composition has a Durometer Hardness (Shore A) of fromabout 60 to about 90 as determined by ASTM D2240. In one aspect, priorto thermoforming, the first polymeric composition has a specific gravityof from about 0.80 g/cm³ to about 1.30 g/cm³ as determined by ASTM D792.In one aspect, prior to thermoforming, the first polymeric compositionhas a melt flow index of about 2 grams/10 minutes to about 50 grams/10minutes at 160 degrees Celsius using a test weight of 2.16 kilograms. Inone aspect, prior to thermoforming, the first polymeric composition hasa melt flow rate greater than about 2 grams/10minutes at 190 degreesCelsius or 200 degrees Celsius when using a test weight of 10 kilograms.In one aspect, prior to thermoforming, the first polymeric compositionhas a modulus of about 1 megapascal to about 500 megapascals.

Thermoplastic Polyurethane Elastomers

In certain aspects, the thermoplastic elastomer is a thermoplasticpolyurethane elastomer. The thermoplastic polyurethane elastomer can bea thermoplastic block polyurethane co-polymer. The thermoplasticpolyurethane co-polymer can be a copolymer comprising hard segments andsoft segments, including blocks of hard segments and blocks of softsegments. The hard segments can comprise or consist of isocyanatesegments. In the same or alternative aspects, the soft segments cancomprise or consist of polyether segments, or polyester segments, or acombination of polyether segments and polyester segments. In one aspect,the thermoplastic material, or the polymeric component of thethermoplastic material, can comprise or consist essentially of anelastomeric thermoplastic polyurethane hard segments and soft segments,such as an elastomeric thermoplastic polyurethane having repeatingblocks of hard segments and repeating blocks of soft segments.

In aspects, one or more of the thermoplastic polyurethane elastomer canbe produced by polymerizing one or more isocyanates with one or morepolyols to produce copolymer chains having carbamate linkages (—N(CO)O—)as illustrated below in Formula 1, where the isocyanate(s) eachpreferably include two or more isocyanate (—NCO) groups per molecule,such as 2, 3, or 4 isocyanate groups per molecule (although,single-functional isocyanates can also be optionally included, e.g., aschain terminating units).

In these embodiments, each R₁ and R₂ independently is an aliphatic oraromatic segment. Optionally, each R₂ can be a hydrophilic segment.

Unless otherwise indicated, any of the functional groups or chemicalcompounds described herein can be substituted or unsubstituted. A“substituted” group or chemical compound, such as an alkyl, alkenyl,alkynyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxyl, ester,ether, or carboxylic ester refers to an alkyl, alkenyl, alkynyl,cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxyl, ester, ether, orcarboxylic ester group, has at least one hydrogen radical that issubstituted with a non-hydrogen radical (i.e., a substituent). Examplesof non-hydrogen radicals (or substituents) include, but are not limitedto, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, ether, aryl,heteroaryl, heterocycloalkyl, hydroxyl, oxy (or oxo), alkoxyl, ester,thioester, acyl, carboxyl, cyano, nitro, amino, amido, sulfur, and halo.When a substituted alkyl group includes more than one non-hydrogenradical, the substituents can be bound to the same carbon or two or moredifferent carbon atoms.

Additionally, the isocyanates can also be chain extended with one ormore chain extenders to bridge two or more isocyanates. This can producepolyurethane copolymer chains as illustrated below in Formula 2, whereinR₃ includes the chain extender. As with each R₁ and R₃, each R₃independently is an aliphatic or aromatic segment.

Each segment R₁, or the first segment, in Formulas 1 and 2 canindependently include a linear or branched C₃₋₃₀ segment, based on theparticular isocyanate(s) used, and can be aliphatic, aromatic, orinclude a combination of aliphatic portions(s) and aromatic portion(s).The term “aliphatic” refers to a saturated or unsaturated organicmolecule that does not include a cyclically conjugated ring systemhaving delocalized pi electrons. In comparison, the term “aromatic”refers to a cyclically conjugated ring system having delocalized pielectrons, which exhibits greater stability than a hypothetical ringsystem having localized pi electrons.

Each segment R₁ can be present in an amount of 5 percent to 85 percentby weight, from 5 percent to 70 percent by weight, or from 10 percent to50 percent by weight, based on the total weight of the reactantmonomers.

In aliphatic embodiments (from aliphatic isocyanate(s)), each segment R₁can include a linear aliphatic group, a branched aliphatic group, acycloaliphatic group, or combinations thereof. For instance, eachsegment R₁ can include a linear or branched C₃₋₂₀ alkylene segment(e.g., C₄₋₁₅ alkylene or C₆₋₁₀ alkylene), one or more C₃₋₈ cycloalkylenesegments (e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl,cycloheptyl, or cyclooctyl), and combinations thereof.

Examples of suitable aliphatic diisocyanates for producing thepolyurethane copolymer chains include hexamethylene diisocyanate (HDI),isophorone diisocyanate (IPDI), butylenediisocyanate (BDI),bisisocyanatocyclohexylmethane (HMDI), 2,2,4-trimethylhexamethylenediisocyanate (TMDI), bisisocyanatomethylcyclohexane,bisisocyanatomethyltricyclodecane, norbornane diisocyanate (NDI),cyclohexane diisocyanate (CHDI), 4,4′-dicyclohexylmethane diisocyanate(H12MDI), diisocyanatododecane, lysine diisocyanate, and combinationsthereof.

In aromatic embodiments (from aromatic isocyanate(s)), each segment R₁can include one or more aromatic groups, such as phenyl, naphthyl,tetrahydronaphthyl, phenanthrenyl, biphenylenyl, indanyl, indenyl,anthracenyl, and fluorenyl. Unless otherwise indicated, an aromaticgroup can be an unsubstituted aromatic group or a substituted aromaticgroup, and can also include heteroaromatic groups. “Heteroaromatic”refers to monocyclic or polycyclic (e.g., fused bicyclic and fusedtricyclic) aromatic ring systems, where one to four ring atoms areselected from oxygen, nitrogen, or sulfur, and the remaining ring atomsare carbon, and where the ring system is joined to the remainder of themolecule by any of the ring atoms. Examples of suitable heteroarylgroups include pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl,imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isooxazolyl, thiadiazolyl,oxadiazolyl, furanyl, quinolinyl, isoquinolinyl, benzoxazolyl,benzimidazolyl, and benzothiazolyl.

Examples of suitable aromatic diisocyanates for producing thepolyurethane copolymer chains include toluene diisocyanate (TDI), TDIadducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate(MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate(TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate,para-phenylene diisocyanate (PPDI),3,3′-dimethyldipheny1-4,4′-diisocyanate (DDDI), 4,4′-dibenzyldiisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, andcombinations thereof. In some embodiments, the copolymer chains aresubstantially free of aromatic groups.

In particular aspects, the polyurethane copolymer chains are producedfrom diisocyanates including HMDI, TDI, MDI, H₁₂ aliphatics, andcombinations thereof. For example, the coated fiber as described hereinof the present disclosure can comprise one or more polyurethanecopolymer chains are produced from diisocynates including HMDI, TDI,MDI, H₁₂ aliphatics, and combinations thereof.

In certain aspects, polyurethane chains which are crosslinked (e.g.,partially crosslinked polyurethane copolymers which retain thermoplasticproperties) or which can be crosslinked, can be used in accordance withthe present disclosure. It is possible to produce crosslinked orcrosslinkable polyurethane copolymer chains using multi-functionalisocyanates. Examples of suitable triisocyanates for producing thepolyurethane copolymer chains include TDI, HDI, and IPDI adducts withtrimethyloylpropane (TMP), uretdiones (i.e., dimerized isocyanates),polymeric MDI, and combinations thereof.

Segment R₃ in Formula 2 can include a linear or branched C₂-C₁₀ segment,based on the particular chain extender polyol used, and can be, forexample, aliphatic, aromatic, or polyether. Examples of suitable chainextender polyols for producing the polyurethane copolymer chains includeethylene glycol, lower oligomers of ethylene glycol (e.g., diethyleneglycol, triethylene glycol, and tetraethylene glycol), 1,2-propyleneglycol, 1,3-propylene glycol, lower oligomers of propylene glycol (e.g.,dipropylene glycol, tripropylene glycol, and tetrapropylene glycol),1,4-butylene glycol, 2,3-butylene glycol, 1,6-hexanediol,1,8-octanediol, neopentyl glycol, 1,4-cyclohexanedimethanol,2-ethyl-1,6-hexanediol, 1-methyl-1,3-propanediol,2-methyl-1,3-propanediol, dihydroxyalkylated aromatic compounds (e.g.,bis(2-hydroxyethyl) ethers of hydroquinone and resorcinol,xylene-α,α-diols, bis(2-hydroxyethyl) ethers of xylene-α,α-diols, andcombinations thereof.

Segment R₂ in Formula 1 and 2 can include a polyether group, a polyestergroup, a polycarbonate group, an aliphatic group, or an aromatic group.Each segment R₂ can be present in an amount of 5 percent to 85 percentby weight, from 5 percent to 70 percent by weight, or from 10 percent to50 percent by weight, based on the total weight of the reactantmonomers.

Optionally, in some examples, the thermoplastic polyurethane elastomercan be a thermoplastic polyurethane having relatively high degree ofhydrophilicity. For example, the thermoplastic polyurethane can be athermoplastic polyether polyurethane in which segment R₂ in Formulas 1and 2 includes a polyether group, a polyester group, a polycarbonategroup, an aliphatic group, or an aromatic group, wherein the aliphaticgroup or aromatic group is substituted with one or more pendant grouphaving relatively greater degree of hydrophilicity (i.e., relatively“hydrophilic” groups). The relatively “hydrophilic” groups can beselected from the group consisting of hydroxyl, polyether, polyester,polylactone (e.g., polyvinylpyrrolidone (PVP)), amino, carboxylate,sulfonate, phosphate, ammonium (e.g., tertiary and quaternary ammonium),zwitterion (e.g., a betaine, such as poly(carboxybetaine (pCB) andammonium phosphonates such as phosphatidylcholine), and combinationsthereof. In such examples, this relatively hydrophilic group or segmentof R₂ can form portions of the polyurethane backbone, or can be graftedto the polyurethane backbone as a pendant group. In some examples, thependant hydrophilic group or segment can be bonded to the aliphaticgroup or aromatic group through a linker. Each segment R₂ can be presentin an amount of 5 percent to 85 percent by weight, from 5 percent to 70percent by weight, or from 10 percent to 50 percent by weight, based onthe total weight of the reactant monomers.

In some examples, at least one R₂ segment of the thermoplasticpolyurethane elastomer includes a polyether segment (i.e., a segmenthaving one or more ether groups). Suitable polyethers include, but arenot limited to polyethylene oxide (PEO), polypropylene oxide (PPO),polytetrahydrofuran (PTHF), polytetramethylene oxide (P T_(m)O), andcombinations thereof. The term “alkyl” as used herein refers to straightchained and branched saturated hydrocarbon groups containing one tothirty carbon atoms, for example, one to twenty carbon atoms, or one toten carbon atoms. The term C_(n) means the alkyl group has “n” carbonatoms. For example, C₄ alkyl refers to an alkyl group that has 4 carbonatoms. C₁₋₇ alkyl refers to an alkyl group having a number of carbonatoms encompassing the entire range (i.e., 1 to 7 carbon atoms), as wellas all subgroups (e.g., 1-6, 2-7, 1-5, 3-6, 1, 2, 3, 4, 5, 6, and 7carbon atoms). Non-limiting examples of alkyl groups include, methyl,ethyl, n-propyl, isopropyl, n-butyl, sec-butyl (2-methylpropyl), t-butyl(1,1- dimethylethyl), 3,3-dimethylpentyl, and 2-ethylhexyl. Unlessotherwise indicated, an alkyl group can be an unsubstituted alkyl groupor a substituted alkyl group.

In some examples of the thermoplastic polyurethane elastomer, the atleast one R₂ segment includes a polyester segment. The polyester segmentcan be derived from the polyesterification of one or more dihydricalcohols (e.g., ethylene glycol, 1,3-propylene glycol, 1,2-propyleneglycol, 1,4-butanediol, 1,3-butanediol,2-methylpentanediol-1,5,diethylene glycol, 1,5-pentanediol,1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, andcombinations thereof) with one or more dicarboxylic acids (e.g., adipicacid, succinic acid, sebacic acid, suberic acid, methyladipic acid,glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid andcitraconic acid and combinations thereof). The polyester also can bederived from polycarbonate prepolymers, such as poly(hexamethylenecarbonate) glycol, poly(propylene carbonate) glycol, poly(tetramethylenecarbonate)glycol, and poly(nonanemethylene carbonate) glycol. Suitablepolyesters can include, for example, polyethylene adipate (PEA),poly(1,4-butylene adipate), poly(tetramethylene adipate),poly(hexamethylene adipate), polycaprolactone, polyhexamethylenecarbonate, poly(propylene carbonate), poly(tetramethylene carbonate),poly(nonanemethylene carbonate), and combinations thereof.

In various of the thermoplastic polyurethane elastomer, at least one R₂segment includes a polycarbonate segment. The polycarbonate segment canbe derived from the reaction of one or more dihydric alcohols (e.g.,ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol,1,4-butanediol, 1,3-butanediol, 2-methylpentanediol-1,5, diethyleneglycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol,cyclohexanedimethanol, and combinations thereof) with ethylenecarbonate.

In various examples of the thermoplastic polyurethane elastomer, atleast one R₂ segment can include an aliphatic group substituted with oneor more groups having a relatively greater degree of hydrophilicity,i.e., a relatively “hydrophilic” group. The one or more relativelyhydrophilic group can be selected from the group consisting of hydroxyl,polyether, polyester, polylactone (e.g., polyvinylpyrrolidone), amino,carboxylate, sulfonate, phosphate, ammonium (e.g., tertiary andquaternary ammonium), zwitterion (e.g., a betaine, such aspoly(carboxybetaine (pCB) and ammonium phosphonates such asphosphatidylcholine), and combinations thereof. In some examples, thealiphatic group is linear and can include, for example, a C₁₋₂₀ alkylenechain or a C₁₋₂₀ alkenylene chain (e.g., methylene, ethylene, propylene,butylene, pentylene, hexylene, heptylene, octylene, nonylene, decylene,undecylene, dodecylene, tridecylene, ethenylene, propenylene,butenylene, pentenylene, hexenylene, heptenylene, octenylene,nonenylene, decenylene, undecenylene, dodecenylene, tridecenylene). Theterm “alkylene” refers to a bivalent hydrocarbon. The term C_(n) meansthe alkylene group has “n” carbon atoms. For example, C₁₋₆ alkylenerefers to an alkylene group having, e.g., 1, 2, 3, 4, 5, or 6 carbonatoms. The term “alkenylene” refers to a bivalent hydrocarbon having atleast one double bond.

In some cases, at least one R₂ segment includes an aromatic groupsubstituted with one or more relatively hydrophilic group. The one ormore hydrophilic group can be selected from the group consisting ofhydroxyl, polyether, polyester, polylactone (e.g.,polyvinylpyrrolidone), amino, carboxylate, sulfonate, phosphate,ammonium (e.g., tertiary and quaternary ammonium), zwitterionic (e.g., abetaine, such as poly(carboxybetaine (pCB) and ammonium phosphonategroups such as phosphatidylcholine), and combinations thereof. Suitablearomatic groups include, but are not limited to, phenyl, naphthyl,tetrahydronaphthyl, phenanthrenyl, biphenylenyl, indanyl, indenyl,anthracenyl, fluorenylpyridyl, pyrazinyl, pyrimidinyl, pyrrolyl,pyrazolyl, imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isooxazolyl,thiadiazolyl, oxadiazolyl, furanyl, quinolinyl, isoquinolinyl,benzoxazolyl, benzimidazolyl, and benzothiazolyl groups, andcombinations thereof.

In various aspects, the aliphatic and aromatic groups can be substitutedwith one or more pendant relatively hydrophilic and/or charged groups.In some aspects, the pendant hydrophilic group includes one or more(e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) hydroxyl groups. In variousaspects, the pendant hydrophilic group includes one or more (e.g., 2, 3,4, 5, 6, 7, 8, 9, 10 or more) amino groups. In some cases, the pendanthydrophilic group includes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10or more) carboxylate groups. For example, the aliphatic group caninclude one or more polyacrylic acid group. In some cases, the pendanthydrophilic group includes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10or more) sulfonate groups. In some cases, the pendant hydrophilic groupincludes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more)phosphate groups. In some examples, the pendant hydrophilic groupincludes one or more ammonium groups (e.g., tertiary and/or quaternaryammonium). In other examples, the pendant hydrophilic group includes oneor more zwitterionic groups (e.g., a betaine, such aspoly(carboxybetaine (pCB) and ammonium phosphonate groups such as aphosphatidylcholine group).

In some aspects, the R₂ segment can include charged groups that arecapable of binding to a counterion to ionically crosslink thethermoplastic elastomer and form ionomers. In these aspects, forexample, R₂ is an aliphatic or aromatic group having pendant amino,carboxylate, sulfonate, phosphate, ammonium, or zwitterionic groups, orcombinations thereof.

In various cases when a pendant hydrophilic group is present, thependant “hydrophilic” group is at least one polyether group, such as twopolyether groups. In other cases, the pendant hydrophilic group is atleast one polyester. In various cases, the pendant hydrophilic group ispolylactone group (e.g., polyvinylpyrrolidone). Each carbon atom of thependant hydrophilic group can optionally be substituted with, e.g., aC₁₋₆ alkyl group. In some of these aspects, the aliphatic and aromaticgroups can be graft polymeric groups, wherein the pendant groups arehomopolymeric groups (e.g., polyether groups, polyester groups,polyvinylpyrrolidone groups).

In some aspects, the pendant hydrophilic group is a polyether group(e.g., a polyethylene oxide group, a polyethylene glycol group), apolyvinylpyrrolidone group, a polyacrylic acid group, or combinationsthereof.

As described herein, the thermoplastic polyurethane elastomer can bephysically crosslinked through e.g., nonpolar or polar interactionsbetween the urethane or carbamate groups on the polymers (the hardsegments. In these aspects, component R₁ in Formula 1, and components R₁and R₃ in Formula 2, forms the portion of the polymer often referred toas the “hard segment”, and component R₂ forms the portion of the polymeroften referred to as the “soft segment”. In these aspects, the softsegment can be covalently bonded to the hard segment. In some examples,the thermoplastic polyurethane elastomer having physically crosslinkedhard and soft segments can be a hydrophilic thermoplastic polyurethaneelastomer (i.e., a thermoplastic polyurethane elastomer includinghydrophilic groups as disclosed herein).

In one aspect, prior to thermoforming, the thermoplastic polyurethaneelastomer is an aromatic polyester thermoplastic elastomericpolyurethane or an aliphatic polyester thermoplastic elastomericpolyurethane having the following properties: (1) a glass transitiontemperature glass transition temperature of from about 20 degreesCelsius to about −60 degrees Celsius; (2) a Taber Abrasion Resistance offrom about 10 milligrams to about 40 milligrams as determined by ASTMD3389; (3) a Durometer Hardness (Shore A) of from about 60 to about 90as determined by ASTM D2240; (4) a specific gravity of from about 0.80g/cm³ to about 1.30 g/cm³ as determined by ASTM D792; (5) a melt flowindex of about 2 grams/10 minutes to about 50 grams/10 minutes at 160degrees Celsius using a test weight of 2.16 kilograms; (6) a melt flowrate greater than about 2 grams/10 minutes at 190 degrees Celsius or 200degrees Celsius when using a test weight of 10 kilograms; and (7) amodulus of about 1 megapascal to about 500 megapascals.

Commercially available thermoplastic polyurethane elastomers havinggreater hydrophilicity suitable for the present use include, but are notlimited to those under the tradename “TECOPHILIC”, such as TG-500,TG-2000, SP-80A-150, SP-93A-100, SP-60D-60 (Lubrizol, Countryside,Ill.), “ESTANE” (e.g., 58238, T470A; Lubrizol, Countryside, Ill.), and“ELASTOLLAN” (e.g., 9339, B70A; BASF).

In various aspects, the thermoplastic polyurethane elastomer can bepartially covalently crosslinked, as previously described herein.

Thermoplastic Styrenic Copolymer Elastomers

In certain aspects, the thermoplastic elastomer is a thermoplasticelastomeric styrenic copolymer. Examples of these copolymers include,but are not limited to, styrene butadiene styrene (SBS) block copolymer,a styrene ethylene/butylene styrene (SEBS) resin, a polyacetal resin(POM) a styrene acrylonitrile resin (SAN), or a blend, alloy, orcompound thereof. Exemplary commercially available thermoplasticelastomeric styrenic copolymers include MONOPRENE IN5074, SP066070, andSP16975 (Teknor Apex, Pawtucket, R.I., USA), which are styreneethylene/butylene styrene (SEBS) resins. In some aspects, blends,alloys, and compounds should be melt compatible or can be compatibilizedwith additives, oils, or grafted chemical moieties in order to achievemiscibility.

In one aspect, the thermoplastic elastomeric styrenic copolymer includesat least one block as illustrated below in Formula 3:

In another aspect, the thermoplastic elastomeric styrenic copolymer canbe a SBS block copolymer comprising a first polystyrene block (block mof Formula 4), a polybutadiene block (block o of Formula 4), and asecond polystyrene block (block p of Formula 4), wherein the SBS blockcopolymer has the general structure shown in Formula 4 below:

In another aspect, the thermoplastic elastomeric styrenic copolymer canbe an SEBS block copolymer comprising a first polystyrene block (block xof Formula 5), a polyolefin block (block y of Formula 5), wherein thepolyolefin block comprises alternating polyethylene blocks (block v ofFormula 5) and polybutylene blocks (block w of Formula 4), and a secondpolystyrene block (block z of Formula 5) as seen in Formula 5 below.

In one aspect, SEBS polymers have a density from about 0.88 grams percubic centimeter to about 0.92 grams per cubic centimeter. In a furtheraspect, SEBS polymers can be as much as 15 to 25 percent less dense thancross-linked rubbers, cross-linked polyurethanes, and thermoplasticpolyurethane materials. In a further aspect, a less dense coatingcomposition offers weight savings and per part cost savings for the samematerial of volume employed while achieving similar performance.

Additives

In some aspects, the films, fibers, and yarns described herein canfurther comprise an additive. The additive can be incorporated directlyinto the films, fibers, and yarns, or alternatively, applied thereto.Additives that can be used include, but are not limited to, dyes,pigments, colorants, ultraviolet light absorbers, hindered amine lightstabilizers, antioxidants, processing aids or agents, plasticizers,lubricants, emulsifiers, pigments, dyes, optical brighteners, rheologyadditives, catalysts, heat stabilizers, flow-control agents, slipagents, lubricating agents, crosslinking agents, crosslinking boosters,halogen scavengers, smoke inhibitors, flameproofing agents, antistaticagents, fillers, or mixtures of two or more of the foregoing. When used,an additive can be present in an amount of from about 0.01 weightpercent to about 10 weight percent, about 0.025 weight percent to about5 weight percent, or about 0.1 weight percent to 3 weight percent, wherethe weight percent is based upon the sum of the material components inthe film, fiber, filament or yarn.

Individual components can be mixed together with the other components ofthe thermoplastic elastomer(s) in a continuous mixer or a batch mixer,e.g., in an intermeshing rotor mixer, such as an Intermix mixer, a twinscrew extruder, in a tangential rotor mixer such as a Banbury mixer,using a two-roll mill, or some combinations of these to make acomposition comprising a thermoplastic polymer and an additive. Themixer can blend the components together via a single step or multiplesteps, and can mix the components via dispersive mixing or distributivemixing to form the resulting thermoplastic composition. This step isoften referred to as “compounding.”

All technical and scientific terms used herein, unless definedotherwise, have the same meaning as commonly understood by one ofordinary skill in the art to which this disclosure belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andrelevant art and should not be interpreted in an idealized or overlyformal sense unless expressly defined herein.

The terms “comprises,” “comprising,” “including,” and “having,” areinclusive and therefore specify the presence of features, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, steps, operations,elements, components, and/or groups thereof.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a coated fiber,”“an uncoated fiber,” or “a knit upper,” including, but not limited to,two or more such coated fibers.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items.

The terms first, second, third, etc. can be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms can be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

As used herein, the modifiers “upper,” “lower,” “top,” “bottom,”“upward,” “downward,” “vertical,” “horizontal,” “longitudinal,”“transverse,” “front,” “back” etc., unless otherwise defined or madeclear from the disclosure, are relative terms meant to place the variousstructures or orientations of the structures of the article of footwearin the context of an article of footwear worn by a user standing on aflat, horizontal surface.

It should be noted that ratios, concentrations, amounts, and othernumerical data can be expressed herein in a range format. Where thestated range includes one or both of the limits, ranges excluding eitheror both of those included limits are also included in the disclosure,e.g. the phrase “x to y” includes the range from ‘x’ to ‘y’ as well asthe range greater than ‘x’ and less than ‘y’. The range can also beexpressed as an upper limit, e.g. ‘about x, y, z, or less’ and should beinterpreted to include the specific ranges of ‘about x’, ‘about y’, and‘about z’ as well as the ranges of ‘less than x’, less than y’, and‘less than z’. Likewise, the phrase ‘about x, y, z, or greater’ shouldbe interpreted to include the specific ranges of ‘about x’, ‘about y’,and ‘about z’ as well as the ranges of ‘greater than x’, greater thany’, and ‘greater than z’. In addition, the phrase “about ‘x’ to ‘y’”,where ‘x’ and ‘y’ are numerical values, includes “about ‘x’ to about‘y’”. It is to be understood that such a range format is used forconvenience and brevity, and thus, should be interpreted in a flexiblemanner to include not only the numerical values explicitly recited asthe limits of the range, but also to include all the individualnumerical values or sub-ranges encompassed within that range as if eachnumerical value and sub-range is explicitly recited. To illustrate, anumerical range of “about 0.1 percent to 5 percent” should beinterpreted to include not only the explicitly recited values of about0.1 percent to about 5 percent, but also include individual values(e.g., 1 percent, 2 percent, 3 percent, and 4 percent) and thesub-ranges (e.g., 0.5 percent, 1.1 percent, 2.4 percent, 3.2 percent,and 4.4 percent) within the indicated range.

As used herein, the terms “about,” “approximate,” “at or about,” and“substantially” mean that the amount or value in question can be theexact value or a value that provides equivalent results or effects asrecited in the claims or taught herein. That is, it is understood thatamounts, sizes, formulations, parameters, and other quantities andcharacteristics are not and need not be exact, but can be approximateand/or larger or smaller, as desired, reflecting tolerances, conversionfactors, rounding off, measurement error and the like, and other factorsknown to those of skill in the art such that equivalent results oreffects are obtained. In some circumstances, the value that providesequivalent results or effects cannot be reasonably determined. In suchcases, it is generally understood, as used herein, that “about” and “ator about” mean the nominal value indicated ±10 percent variation unlessotherwise indicated or inferred. In general, an amount, size,formulation, parameter or other quantity or characteristic is “about,”“approximate,” or “at or about” whether or not expressly stated to besuch. It is understood that where “about,” “approximate,” or “at orabout” is used before a quantitative value, the parameter also includesthe specific quantitative value itself, unless specifically statedotherwise.

Reference to “a” chemical compound” refers to one or more molecules ofthe chemical compound, rather than being limited to a single molecule ofthe chemical compound. Furthermore, the one or more molecules can orcannot be identical, so long as they fall under the category of thechemical compound. Thus, for example, “a polyamide” is interpreted toinclude one or more polymer molecules of the polyamide, where thepolymer molecules can or cannot be identical (e.g., different molecularweights and/or isomers).

The terms “at least one” and “one or more of” an element are usedinterchangeably, and have the same meaning that includes a singleelement and a plurality of the elements, and can also be represented bythe suffix “(s)” at the end of the element. For example, “at least onepolyamide”, “one or more polyamides”, and “polyamide(s)” can be usedinterchangeably and have the same meaning.

As used herein, the terms “optional” or “optionally” means that thesubsequently described component, event or circumstance can or cannotoccur, and that the description includes instances where said component,event or circumstance occurs and instances where it does not.

The term “receiving”, such as for “receiving an upper for an article offootwear”, when recited in the claims, is not intended to require anyparticular delivery or receipt of the received item. Rather, the term“receiving” is merely used to recite items that will be referred to insubsequent elements of the claim(s), for purposes of clarity and ease ofreadability.

As used herein the terms “weight percent” and “wt percent,” which can beused interchangeably, indicate the percent by weight of a givencomponent based on the total weight of the composition, unless otherwisespecified. That is, unless otherwise specified, all wt percent valuesare based on the total weight of the composition. It should beunderstood that the sum of wt percent values for all components in adisclosed composition or formulation are equal to 100.

Compounds are described using standard nomenclature. For example, anyposition not substituted by any indicated group is understood to haveits valence filled by a bond as indicated, or a hydrogen atom. A dash(“-”) that is not between two letters or symbols is used to indicate apoint of attachment for a substituent. For example, -CHO is attachedthrough carbon of the carbonyl group. Unless defined otherwise,technical and scientific terms used herein have the same meaning as iscommonly understood by one of skill in the art to which this inventionbelongs.

Unless otherwise specified, temperatures referred to herein aredetermined at standard atmospheric pressure (i.e., 1 ATM).

Property Analysis and Characterization Procedures

Evaluation of various properties and characteristics described hereinare by various testing procedures as described herein below.

Sample Coefficient of Friction. The static or dynamic coefficient offriction (COF) of a textile or plaque sample is determined using testmethod ASTM D1894. In this method, a sample is cut to size and mountedon the sled, and a 100 gram weight plate is placed on the sled. Duringthe test, the weighted sled is pulled across a test surface of thematerial being tested. For example, static and dynamic wet and dry COFcan be determined by pulling the sled across a concrete surface todetermine the COF of the sample and concrete. The coefficient offriction of the sample against that surface is captured by recording thenormal force (100 grams plus sled weight) and measuring the appliedforce required to drag the sled across the test surface. The coefficientof friction (COF) is then calculated from the ratio of the two forces.Dry COF is determined by testing a dry sample against a dry testingsurface, and wet COF is determined by testing a sample wetted with waterby soaking it in room temperature water for 10 minutes against a testsurface wetted with room temperature water.

Textile-Ball Coefficient of Friction Test. The static and dynamiccoefficient of friction (COF) of a sample prepared using the ComponentSampling Procedure or the Textile Sampling Procedure described belowagainst a sample from a panel of a “MERLIN” soccer ball (Nike Inc.,Beaverton, Oreg., USA) is determined using a modified version of testmethod ASTM D1894. In this method, the sample is cut to size and mountedon an acrylic substrate, and the ball material is cut to size andmounted on the sled. Once the ball material has been mounted on thesled, the sled has a contact footprint of 3.9 inches by 1 inch, and aweight of approximately 1.7 kilograms. During the test, the sample andball material are positioned with the outer surface of the ball materialcontacting the surface of the sample which is intended form the outersurface of an article of footwear, and the sled is pulled across thesample. Dry samples and dry ball material are used to determine thestatic or dynamic dry COF. To determine the static or dynamic wet COF,the sample and the ball material are both soaked in room temperaturewater for 10 minutes immediately prior to testing. Each measurement isrepeated at least 3 times, and the results of the runs are averaged.

Whole Footwear Coefficient of Friction Test. Testing on whole articlesof footwear to determine the outsole's COF is performed using the SATRATM144 test method, which forms the basis for the EN ISO 13287 and ASTMF2913-11 test methods. Testing is conducted on whole articles offootwear, i.e., an upper attached to a sole structure including theoutsole to be tested. The whole article of footwear can either be a new,unworn article of footwear, or can be an article of footwear which hasbeen mechanically abraded in accordance with the Whole Footwear AbrasionTest. Each article of footwear to be tested is aged 24 hours in the testlab prior to performing testing. This test is run using heel andforefoot substrate contact modes to generate coefficient of frictiondata. Each article of footwear can be tested on one of two surfaces inwet and dry conditions: (1) quarry tile, and (2) smooth concrete.Footwear tested using the Whole Footwear Coefficient of Friction Testwhen new can subsequently be subjected to abrasion using the WholeFootwear Abrasion Test and then re-tested using the Whole FootwearCoefficient of Friction Test to simulate the traction and slipresistance of the footwear on surfaces after the equivalent of many daysor miles worth of simulated wear. Coefficient of friction is calculatedfrom the applied force to laterally translate the outsole of the shoeacross the substrate divided by the applied normal force loaded on thesample as specified in the test method.

Whole Footwear Abrasion Test. Biomechanical abrasion testing isperformed on outsoles of whole articles of footwear using the SATRATM362 testing method. In this test, a walking action over a real wearsurface is simulated. Sample footwear is mounted on a mechanical leg anda flooring mechanism rotates to simulate turns during walking with theforepart of the sole in contact with the walking surface. The forceapplied by the footwear on the sample flooring surface follows adistinct profile that can be adjusted by adding or subtracting weights.A standard load of 180 pounds is used, and the speed can be adjusted toreplicate normal walking, running, and/or sprinting. The walking surfaceis a textured concrete slab. Samples are conditioned for 24 hours in aclimate controlled lab and inserted into the machine. Each sample istested for 48 hours of simulated foot strikes, or about 96,000 steps,which approximates 100 miles of walking. Mass loss is recorded at 24hours and at 48 hours of testing.

Melting and Glass Transition Temperature Test. The melting temperatureand/or glass transition temperature are determined for a sample preparedaccording to Material Sampling Procedure described below, using acommercially available Differential Scanning Calorimeter (“DSC”) inaccordance with ASTM D3418-97. Briefly, a 10-60 milligram sample isplaced into an aluminum DSC pan and then the lid is sealed with acrimper press. The DSC is configured to scan from −100 degrees Celsiusto 225 degrees Celsius with a 20 degree Celsius/minute heating rate,hold at 225 degrees Celsius for 2 minutes, and then cool down to 25degrees Celsius at a rate of −20 degrees Celsius/minute. The DSC curvecreated from this scan is then analyzed using standard techniques todetermine the glass transition temperature and the melting temperature.Melting enthalpy is calculated by integrating the melting endotherm andnormalizing by the mass of the sample. Crystallization enthalpy uponcooling is calculated by integrating the cooling endotherm andnormalizing by the mass of the sample.

Deformation Temperature Test. The Vicat softening temperature isdetermined for a sample prepared according to Material SamplingProcedure or the Component Sampling Procedure described below, accordingto the test method detailed in ASTM Tm D1525-09 Standard Test Method forVicat Softening Temperature of Plastics, preferably using Load A andRate A. Briefly, the Vicat softening temperature is the temperature atwhich a flat-ended needle penetrates the specimen to the depth of 1millimeter under a specific load. The temperature reflects the point ofsoftening expected when a material is used in an elevated temperatureapplication. It is taken as the temperature at which the specimen ispenetrated to a depth of 1 millimeter by a flat-ended needle with a 1square millimeter2 circular or square cross-section. For the Vicat Atest, a load of 10 Newtons (N) is used, whereas for the Vicat B test,the load is 50 Newtons. The test involves placing a test specimen in thetesting apparatus so that the penetrating needle rests on its surface atleast 1 millimeter from the edge. A load is applied to the specimen perthe requirements of the Vicat A or Vicat B test. The specimen is thenlowered into an oil bath at 23° C. degrees Celsius. The bath is raisedat a rate of 50 degrees Celsius or 120 degrees Celsius per hour untilthe needle penetrates 1 millimeter. The test specimen must be between 3and 6.5 millimeter thick and at least 10 millimeter in width and length.No more than three layers can be stacked to achieve minimum thickness.

Melt Flow Index Test. The melt flow index is determined for a sampleprepared according to the Material Sampling Procedure described belowaccording to the test method detailed in ASTM D1238-13 Standard TestMethod for Melt Flow Rates of Thermoplastics by Extrusion Plastometer,using Procedure A described therein. Briefly, the melt flow indexmeasures the rate of extrusion of thermoplastics through an orifice at aprescribed temperature and load. In the test method, approximately 7grams of the material is loaded into the barrel of the melt flowapparatus, which has been heated to a temperature specified for thematerial. A weight specified for the material is applied to a plungerand the molten material is forced through the die. A timed extrudate iscollected and weighed. Melt flow index values are calculated in g/10 minfor a given applied load and applied temperature. As described in ASTMD1238-13, melt flow index can be determined at 160 degrees Celsius usinga weight of 2.16 kg, or at 200 degrees Celsius using a weight of 10 kg.

Molten Polymer Viscosity Test. The test is conducted using 2 millimeterplaques or films prepared according to the Plaque or Film SamplingProcedure described below. A circular die is used to cut 50 millimeterspecimen discs of from the plaque or film. Test specimens are mounted ona 50 millimeter diameter aluminum parallel plate on an ARES-G2(displacement controlled) rheometer. The top plate is lowered so thatthe test specimens are in contact with both disc surfaces under adefined normal force load and the stage is heated to 210 degreesCelsius. Samples are equilibrated until molten, for a defined dwell timeof minutes, and oscillatory shear frequency sweeps are applied at lowstrain amplitudes to gather rate-dependent data. The ratio of theapplied shear stress required to generate the oscillatory motion at agiven shear frequency rate yields the measured viscosity value. Shearrate-dependent viscosity data can be gathered from 0.1 reciprocalseconds to 1000 reciprocal seconds.

Plaque Modulus Test. The modulus for sample prepared according to thePlaque or Film Sampling Procedure described below is determinedaccording to the test method detailed in ASTM D412-98 Standard TestMethods for Vulcanized Rubber and Thermoplastic Rubbers andThermoplastic Elastomers-Tension, with the following modifications. Thesample dimension is the ASTM D412-98 Die C, and the sample thicknessused is 2.0 millimeters plus or minus 0.5 millimeters. The grip typeused is a pneumatic grip with a metal serrated grip face. The gripdistance used is 75 millimeters. The loading rate used is 500millimeters/minute. The modulus (initial) is calculated by taking theslope of the stress (MPa) versus the strain in the initial linearregion. This test can also be used to determine other tensile propertiessuch as break strength, strain to break, load at 100 percent strain,toughness, stiffness, tear strength, and the like.

Yarn Denier and Thickness Test. To determine denier, a sample of yarn isprepared according to the Yarn Sampling Procedure described below. Aknown length of the yarn sample and its corresponding weight aremeasured. This is converted to grams per 9000 meters of yarn. Todetermine the thickness of a coated yarn, the yarn is first cut with arazor and observed under a microscope, where coating thickness relativeto core yarn diameter is determined to scale.

Yarn Modulus, Tenacity, and Elongation Test. The modulus for a yarn isdetermined for a sample prepared according to the Yarn SamplingProcedure described above, and tested according to the test methoddetailed in EN ISO 2062 (Textiles-Yarns from Packages)—Determination ofSingle-End Breaking Force and Elongation at Break Using Constant Rate ofExtension (CRE) Tester. The following modifications to the test methodare used. 5 test specimens are prepared with a sample length of 600millimeters. The equipment used is an Instron Universal Testing System.Instron Pneumatic cord and Thread Grips or similar pneumatic grips areinstalled, with a grip distance of 250 millimeters. Grip distance is setto 145+1 millimeter and gauge length is set at 250+2 millimeters whenusing Instron Pneumatic Cord and Thread Grips. The pre-loading is set to5 grams and the loading rate used is 250 millimeters/minute. The modulus(initial) is calculated by taking the slope of the stress (MPa) versusthe strain in the initial linear region. Maximum tensile force value isrecorded. Tenacity and elongation of the yarn sample are determinedaccording to the test method detailed in EN ISO 2062 with the pre-loadset to 5 grams. Elongation is recorded at the maximum tensile forcevalue applied prior to breaking. Tenacity can be calculated as the ratioof load required to break the specimen to the linear density of thespecimen.

Durometer Hardness Test. The hardness of a material is determined for asample prepared according to the Material Sampling Procedure, theComponent Sampling Procedure, the Plaque or Film Sampling Procedure, orthe Textile Sampling Procedure described below, according to the testmethod detailed in ASTM D-2240 Durometer Hardness, using a Shore Ascale.

Specific Gravity Test. The specific gravity for a sample preparedaccording to the Material Sampling Procedure, the Component SamplingProcedure, the Plaque or Film Sampling Procedure, the Yarn SamplingProcedure, or the Textile Sampling Procedure described below isdetermined according to the test method detailed in ASTM D792 usingvolume displacement.

Yarn Shrinkage Test. The free-standing shrinkage of yarns can bedetermined by the following method. A yarn sample is prepared accordingto the Yarn Sampling Procedure described below, and is cut to a lengthof approximately 30 millimeters with minimal tension at approximatelyroom temperature (e.g., 20 degrees Celsius). The cut sample is placed ina 50 degrees Celsius or 70 degrees Celsius oven for 90 seconds. Thesample is removed from the oven and measured. The percentage of shrinkis calculated using the pre-and post-oven measurements of the sample, bydividing the post-oven measurement by the pre-oven measurement, andmultiplying by 100.

Cold Ross Flex Test. The cold Ross flex test is determined using asample prepared according to the Plaque or Film Sampling Proceduredescribed below according the following test method. The purpose of thistest is to evaluate the resistance to cracking of a sample underrepeated flexing to 60 degrees in a cold environment. The plaque sampleis sized to fit inside the flex tester machine. Each material is testedas five separate samples. The flex tester machine is capable of flexingsamples to 60 degrees at a rate of 100±5 cycles per minute. The mandreldiameter of the machine is 10 millimeters. Suitable machines for thistest include the Emerson AR-6, the Satra S T_(m) 141F, the GotechGT-7006, and the Shin II Scientific SI-LTCO (DaeSung Scientific). Thesample(s) are inserted into the machine according to the specificparameters of the flex machine used. The machine is placed in a freezerset to −6 degrees Celsius for the test. The motor is turned on to beginflexing with the flexing cycles counted until the sample cracks.Cracking of the sample means that the surface of the material isphysically split. Visible creases of lines that do not actuallypenetrate the surface are not cracks. The sample is measured to a pointwhere it has cracked but not yet broken in two.

Bally Flex Test. The Bally flex test, which is based on standard methodsincluding ISO 5402, ISO 32100, SATRA TM55, DIN 53351, and BS-3144, isconducted as follows, using samples prepared according to the ComponentSampling Procedure, the Plaque or Film Sampling Procedure, or theTextile Sampling Procedure described below. A minimum of 6 samples arerequired for this test method. Samples are 60 millimeters×75 millimetersand can be hand cut or die cut. Each sample is folded and inserted intothe testing equipment such that it protrudes from the bottom clamp adistance equal to the sample thickness. The folded front edge of thesample is perpendicular to the base of the testing machine. The samplesare then repeatedly flexed. Samples are visually inspected during thetest period. If a sample has cracked, the approximate number of cycleswhen cracking occurred is noted. If this sample is the only sample beingtested on the machine, the test is stopped since the material hasfailed. If other samples are being tested, the testing continues untileither all samples have failed or until 100,000 cycles have beencompleted, whichever occurs first.

Wet Bally Flex Test. The wet Bally flex test is designed to assess theability of a sample textile, film, or other specimen to resist waterpenetration from repeated flexing and is conducted as follows usingsamples prepared according to the Component Sampling Procedure, thePlaque or Film Sampling Procedure, or the Textile Sampling Proceduredescribed below. At a minimum, 4 samples are required. Specimens are 60millimeters×75 millimeters and can be hand cut or die cut. 1 gram ofsodium chloride is dissolved in 1 liter of distilled water and stirredto create a sodium chloride solution. The sodium chloride solution ispoured into a water tank and placed into the testing machine. A GotechGT-7071-DWN instrument (Gotech Testing Machines, Taichung City, Taiwan)or similar instrument can be used for analysis. Specimens are foldedinto a U shape and clamped into the instrument such that the side of thespecimens to be tested for water penetration faces outward. The samplesare then repeatedly flexed. If a specimen remains intact through atleast 5000 cycles of flexing, it can be considered “water resistant.” Ifa sample remains intact for at least 15,000 cycles of flexing, it can beconsidered “waterproof.” If a specimen leaks, triggering a sensor,before all cycles have been conducted, the specimen is said to fail.

Stoll Abrasion Test. Abrasion resistance, including abrasion resistancesimulating footwear upper scuffing, can be measured using the Stollabrasion test, using samples prepared according to the ComponentSampling Procedure, the Plaque or Film Sampling Procedure, or theTextile Sampling Procedure described below. The minimum number ofsamples for Stoll abrasion testing is 3. Samples used herein were handcut or die cut into circles having a 112 millimeter diameter. The Stollabrasion test is described more fully in ASTM D3886 and can be performedon the Atlas Universal Wear Tester. In the Stoll abrasion test, anabrading medium is moved over the stationary, mounted test sample andthe visual appearance of the sample is monitored. The Stoll abrasiontest is performed under pressure to simulate wear under normal usage.

Akron Abrasion Test. Abrasion resistance, including abrasion resistancesimulating footwear sole structure scuffing of ground-contacting areascan be measured using the Akron abrasion test, using samples preparedaccording to the Component Sampling Procedure, the Plaque or FilmSampling Procedure, or the Textile Sampling Procedure described below. Asample strip is cut from a sample, wherein the strip is approximately2-3 millimeters thick, 0.5 inches (127 millimeters) wide, and 8 inches(2032 millimeters) long. The strip is mounted to the perimeter of arubber wheel, and the wheel is mounted so the strip is pushed against anabrasive grit surface at a slight angle (approximately 15 degrees) andunder a known force (approximately 6 pounds or 2.72 kilograms). Thestrip is run for a number of cycles to prepare the surface, cleaned witha brush and vacuum, and weighed. The strip is then mounted against theabrasive wheel and run for about 3000 additional cycles, then cleanedand weighed again. Mass loss can be adjusted based on the density of thematerial. The measured mass and volume losses represent the abrasionlevel of resistance.

DIN Abrasion Test. Samples are prepared according to the ComponentSampling Procedure, the Plaque or Film Sampling Procedure, or theTextile Sampling Procedure described below Abrasion loss is tested oncylindrical samples with a diameter of 16±0.2 millimeters and a minimumthickness of 6 millimeters cut using a ASTM standard hole drill. Theabrasion loss is measured using Method B of ASTM D 5963-97a on a GotechGT-7012-D abrasion test machine. The tests are performed as 22 degreesCelsius with an abrasion path of 40 meters. The Standard Rubber #1 usedin the tests has a density of 1.336 grams per cubic centimeter (g/cm³).The smaller the abrasion loss volume, the better the abrasionresistance.

Water Penetration Test. Water penetration for a sample is determined asfollows, using for a sample prepared according to the Component SamplingProcedure, the Plaque or Film Sampling Procedure, or the TextileSampling Procedure described below. The specimen to be tested is mountedon a support base with a surface at a 45 degree angle to the horizontal.The support base includes a 152 millimeter diameter specimen holderinner ring. A specimen is allowed to equilibrate in the laboratoryenvironment for at least 2 hours prior to testing. Test specimens arecut into 220 millimeter diameter circles. Thicker or harder materialssuch as leather or stiff synthetic leather will have 3 notches cut intothe outer edge of the sample. Specimens may be hand cut or die cut. Testspecimens for softer materials are cut to the same size, with lengthdirection marked on the test specimens. Backing paper is prepared fromwhite or off-white paper towels, coffee filters, or similar thin,absorbent papers. Backing paper is also cut into 220 millimeter diametercircles. One backing paper is prepared per test specimen and backingpaper is not reused. The backing paper and a specimen are placed in asample fixture, which is in turn placed in a spray testing device. Thesample length direction should be parallel with the water flowdirection. A funnel is adjusted to a height of 6 inches (152.4millimeters) between a spray nozzle and the test specimen. The spraynozzle must be over the center of the test specimen. 250±2 millilitersof distilled water are added to the funnel, which causes water to sprayonto the test specimen. Within 10 seconds of spraying ending, the topsurface is evaluated for water repellency. After the top surface isevaluated, the sample fixture is removed from the support base and thebacking paper is evaluated to determine if water penetrated through thesample. Water penetration is reported after visual assessment andsamples are rated as “pass” or “fail” according to the degree ofwetting. If no sticking or wetting of the top surface is observed, ifslight random sticking or wetting of the top surface is observed, or ifwetting of the top surface is observed at spray points, the sample isconsidered to pass. Further wetting beyond the spray points and/orincluding the back surface indicates the sample has failed the waterpenetration test.

Textile-Ball Impact Test. Test samples of textiles are preparedaccording to the Component Sampling Procedure or the Textile SamplingProcedure described below. A 10 inch by 8 inch test sample of thetextile is mounted on the outer surface on a metal cylinder having a 10inch circumference. The test sample and cylinder are mounted on theswinging arm of a robot, the swinging arm is swung at a rate of 50 milesper hour, and impacts the equator of a stationary ball. The ball used isa regulation size Nike “MERLIN” soccer ball inflated to 0.80 bar. A highspeed video camera is used to record the ball position immediatelyfollowing the impact. Using the position in space and rotation of theball across multiple frames of the images recorded by the high-speedvideo camera, software is then used to calculate the velocity and spinrate of the ball immediately after impact. Each measurement is repeatedat least 3 times, and the results of the runs are averaged.

Upper-Ball Impact Test. A whole men's size 10.5 football boot, or theupper of a men's size 10.5 football boot, is mounted on the swinging armof a robot, and positioned so the ball impacts the boot on the medialside of the vamp, on or near the laces (when the boot includes a lacingstructure), and the upper impacts the equator of the ball when thesinging arm of the robot is swung at a rate of 50 miles per hour. Theball used is a regulation size Nike “MERLIN” soccer ball inflated to0.80 bar. A high speed video camera is used to record the ball positionimmediately following the impact. Using the position in space androtation of the ball across multiple frames of the images recorded bythe high-speed video camera, software is then used to calculate thevelocity and spin rate of the ball immediately after impact. Eachmeasurement is repeated at least 3 times, and the results of the runsare averaged.

Specific Gravity Test

The specific gravity (SG) is measured for samples taken using the PlaqueSampling Procedure, or the Component Sampling Procedure, using a digitalbalance or a Densicom Tester (Qualitest, Plantation, Fla., USA). Eachsample is weighed (g) and then is submerged in a distilled water bath(at 22 degrees C. plus or minus 2 degrees C.). To avoid errors, airbubbles on the surface of the samples are removed, e.g., by wipingisopropyl alcohol on the sample before immersing the sample in water, orusing a brush after the sample is immersed. The weight of the sample inthe distilled water is recorded. The specific gravity is calculated withthe following formula:

${S.G.} = \frac{{Weight}\mspace{14mu}{of}\mspace{11mu}{the}\mspace{14mu}{sample}\mspace{14mu}{in}\mspace{14mu}{air}\mspace{14mu}(g)}{\begin{matrix}{{{Weight}\mspace{14mu}{of}\mspace{11mu}{the}\mspace{14mu}{sample}\mspace{14mu}{in}\mspace{14mu}{air}\mspace{14mu}(g)} -} \\{{Weight}\mspace{14mu}{of}\mspace{11mu}{the}\mspace{14mu}{sample}\mspace{14mu}{in}\mspace{14mu}{water}\mspace{14mu}(g)}\end{matrix}}$

Sampling Procedures

Using the Tests described above, various properties of the materialsdisclosed herein and articles formed therefrom can be characterizedusing samples prepared with the following sampling procedures:

Material Sampling Procedure. The Material Sampling Procedure can be usedto obtain a neat sample of a polymeric composition or of a polymer, or,in some instances, a sample of a material used to form a polymericcomposition or a polymer. The material is provided in media form, suchas flakes, granules, powders, pellets, and the like. If a source of thepolymeric material or polymer is not available in a neat form, thesample can be cut from a component or element containing the polymericmaterial or polymer, such as a composite element or a sole structure,thereby isolating a sample of the material.

Plaque or Film Sampling Procedure. A sample of a polymeric compositionor a polymer is prepared. A portion of the polymer or polymericcomposition is then be molded into a film or plaque sized to fit thetesting apparatus. For example, when using a Ross flexing tester, theplaque or film sample is sized to fit inside the Ross flexing testerused, the sample having dimensions of about 15 centimeters (cm) by 2.5centimeters (cm) and a thickness of about 1 millimeter (mm) to about 4millimeters (mm) by thermoforming the polymeric composition or polymerin a mold. For a plaque sample of a polymer, the sample can be preparedby melting the polymer, charging the molten polymer into a mold,re-solidifying the polymer in the shape of the mold, and removing thesolidified molded sample from the mold. Alternatively, the sample of thepolymer can be melted and then extruded into a film which is cut tosize. For a sample of a polymeric composition, the sample can beprepared by blending together the ingredients of the polymericcomposition, melting the thermoplastic ingredients of the polymericcomposition, charging the molten polymeric composition into a mold,re-solidifying the polymeric composition in the shape of the mold, andremoving the solidified molded sample from the mold. Alternatively, thesample of the polymer material can be prepared by mixing and melting theingredients of the polymeric composition, and then the molten polymericcomposition can be extruded into a film which is cut to size. For a filmsample of a polymer or polymeric composition, the film is extruded as aweb or sheet having a substantially constant film thickness for the film(within ±10 percent of the average film thickness) and cooled tosolidify the resulting web or sheet. A sample having a surface area of 4square centimeters is then cut from the resulting web or sheet.Alternatively, if a source of the film material is not available in aneat form, the film can be cut from a substrate of a footwear component,or from a backing substrate of a co-extruded sheet or web, therebyisolating the film. In either case, a sample having a surface area of 4square centimeters is then cut from the resulting isolated film.

Component Sampling Procedure. This procedure can be used to obtain asample of a material from a component of an article of footwear, anarticle of footwear, a component of an article of apparel, an article ofapparel, a component of an article of sporting equipment, or an articleof sporting equipment, including a sample of a polymeric composition orof a textile, or a portion of a textile, such as thermoformed network. Asample including the material in a non-wet state (e.g., at 25 degreesCelsius and 20 percent relative humidity) is cut from the article orcomponent using a blade. If the material is bonded to one or moreadditional materials, the procedure can include separating theadditional materials from the material to be tested. For example, totest a material on a ground-facing surface of sole structure, theopposite surface can be skinned, abraded, scraped, or otherwise cleanedto remove any adhesives, yarns, fibers, foams, and the like which areaffixed to the material to be tested. The resulting sample includes thematerial and may include any additional materials bonded to thematerial.

The sample is taken at a location along the article or component thatprovides a substantially constant material thickness for the material aspresent on the article or component (within plus or minus 10 percent ofthe average material thickness), such as, for an article of footwear, ina forefoot region, midfoot region, or a heel region of a ground-facingsurface. For many of the test protocols described above, a sample havinga surface area of 4 square centimeters (cm²) is used. The sample is cutinto a size and shape (e.g., a dogbone-shaped sample) to fit into thetesting apparatus. In cases where the material is not present on thearticle or component in any segment having a 4 square centimeter surfacearea and/or where the material thickness is not substantially constantfor a segment having a 4 square centimeter surface area, sample sizeswith smaller cross-sectional surface areas can be taken and thearea-specific measurements are adjusted accordingly.

Yarn Sampling Procedure. Yarn to be tested is stored at room temperature(20 degrees Celsius to 24 degrees Celsius) for 24 hours prior totesting. The first 3 meters of material are discarded. A sample yarn iscut to a length of approximately 30 millimeters with minimal tension atapproximately room temperature (e.g., 20 degrees Celsius).

Textile Sampling Procedure. A textile to be tested is stored at roomtemperature (20 degrees Celsius to 24 degrees Celsius) for 24 hoursprior to testing. The textile sample is cut to size as dictated by thetest method to be used, with minimal tension at approximately roomtemperature (e.g., 20 degrees Celsius).

Before proceeding to the Examples, it is to be understood that thisdisclosure is not limited to particular aspects described, and as suchmay, of course, vary. Other systems, methods, features, and advantagesof foam compositions and components thereof will be or become apparentto one with skill in the art upon examination of the following drawingsand detailed description. It is intended that all such additionalsystems, methods, features, and advantages be included within thisdescription, be within the scope of the present disclosure, and beprotected by the accompanying claims. It is also to be understood thatthe terminology used herein is for the purpose of describing particularaspects only, and is not intended to be limiting. The skilled artisanwill recognize many variants and adaptations of the aspects describedherein. These variants and adaptations are intended to be included inthe teachings of this disclosure and to be encompassed by the claimsherein.

Aspects

The following listing of exemplary aspects supports and is supported bythe disclosure provided herein.

Aspect 1. A textile, comprising:

-   a first network of yarns including a first coated yarn, the first    coated yarn comprising a first core yarn and a first coating    including a first polymeric composition disposed on at least a    portion of an outer surface of the first core yarn, wherein the    first polymeric composition is a thermoplastic elastomeric    composition.

Aspect 2. The textile of Aspect 1, wherein the textile is a knit orcrochet textile, and the first network of yarns includes connected loopsof the first coated yarn.

Aspect 3. The textile of Aspect 1, wherein the textile is a woventextile, and the first network of yarns includes interlaced sets ofyarns comprising the first coated yarn in a warp direction, or in a weftdirection, or in both the warp and weft directions.

Aspect 4. The textile of Aspect 1, wherein the textile is a non-woventextile, and the first network of yarns includes entangled or bondedyarns comprising the first coated yarn.

Aspect 5. The textile of Aspect 4, wherein the entangled or bonded yarnscomprise mechanically entangled yarns, thermally bonded yarns, yarnsbonded by a solvent treatment, chemically bonded yarns, or anycombination thereof.

Aspect 6. The textile of any of Aspects 1-5, wherein the first core yarncomprises a second polymeric composition, and wherein the firstpolymeric composition of the first coating has a first meltingtemperature.

Aspect 7. The textile of Aspect 6, wherein the second polymericcomposition is a second thermoplastic composition having a seconddeformation temperature, and the second deformation temperature is atleast 20 degrees Celsius (C) greater, or optionally at least 50 degreesC. greater, or optionally at least 100 degrees C. greater than the firstmelting temperature of the first thermoplastic composition.

Aspect 8. The textile of Aspect 6 or 7, wherein the second polymericcomposition is a second thermoset composition.

Aspect 9. The textile of any of Aspects 1-8, wherein the first core yarncomprises a first core yarn composition comprising a polyester or apolyamide.

Aspect 10. The textile of any of Aspects 1-9, wherein the first coreyarn has a linear density from about 100 denier to about 300 denier, orhas a diameter of from about 60 to 200 microns.

Aspect 11. The textile of any of Aspects 1-10, wherein the first coatingis axially centered surrounding the core yarn, and the first coatingthickness leads to a nominal average outer diameter of the coated yarnof up to about 1.0 millimeter.

Aspect 12. The textile of any of Aspects 1-11, wherein the first coatingis axially centered surrounding the first core yarn, and the firstcoating thickness leads to a nominal average outer diameter of thecoated yarn of about 0.1 millimeters to about 0.6 millimeters.

Aspect 13. The textile of any of Aspects 1-12, wherein the first coatinghas an average radial coating thickness of about 50 micrometers to about200 micrometers.

Aspect 14. The textile of any of Aspects 1-13, wherein the firstpolymeric composition has a melting temperature greater than about 110degrees C. and less than about 190 degrees C.

Aspect 15. The textile of any of Aspects 1-13, wherein the firstpolymeric composition has a melting temperature greater than about 120degrees C. and less than about 170 degrees C., and optionally greaterthan about 130 degrees C., and less than about 160 degrees C.

Aspect 16. The textile of any of Aspects 1-15, wherein the firstpolymeric composition has a glass transition temperature glasstransition temperature of less than 20 degrees C.

Aspect 17. The textile of any of Aspects 1-16, wherein the firstpolymeric composition has a glass transition temperature glasstransition temperature of from about 20 degrees C. to about −60 degreesC.

Aspect 18. The textile of any of Aspects 1-17, wherein the firstpolymeric composition has a Taber Abrasion Resistance of from about 10milligrams to about 40 milligrams as determined by ASTM D3389.

Aspect 19. The textile of any of Aspects 1-18, wherein the firstpolymeric composition has a Durometer Hardness (Shore A) of from about60 to about 90, from about 60 to about 90, or from about 65 to about 85,or from about 70 to about 80 as determined by ASTM D2240.

Aspect 20. The textile of any of Aspects 1-19, wherein the firstpolymeric composition has a specific gravity of from about 0.80 gramsper cubic centimeter to about 1.30 grams per cubic centimeter, or fromabout 1.0 grams per cubic centimeter to about 1.2 grams per cubiccentimeter as determined by ASTM D792.

Aspect 21. The textile of any of Aspects 1-20, wherein the firstpolymeric composition has a melt flow index of about 2 grams/10 minutesto about 50 grams/10 minutes at 160 degrees C. using a test weight of2.16 kilograms as determined using ASTM D1238-13.

Aspect 22. The textile of any of Aspects 1-21, wherein the firstpolymeric composition has a melt flow index greater than about 2grams/10minutes at 190 degrees C. or 200 degrees C. when using a testweight of 10 kilograms as determined using ASTM D1238-13.

Aspect 23. The textile of any of Aspects 1-22, wherein the firstpolymeric composition has a modulus of about 1 megapascal to about 500megapascals as determined using the Plaque Modulus Test.

Aspect 24. The textile of any of Aspects 1-23, wherein the firstpolymeric composition comprises a polymeric component consisting of allthe polymers present in the polymeric composition; optionally whereinand the polymeric component comprises two or more polymers, wherein thetwo or more polymers differ from each other in chemical structure ofindividual segments of each of the two or more polymers, or in molecularweight of each of the two or more polymers, or in both.

Aspect 25. The textile of any of Aspects 1-24, wherein the firstpolymeric composition comprises a thermoplastic elastomeric styreniccopolymer, a thermoplastic elastomeric polyurethane, or a combinationthereof; optionally wherein the polymeric component of the firstpolymeric composition consists of the thermoplastic elastomeric styreniccopolymer, the thermoplastic elastomeric polyurethane, or thecombination thereof.

Aspect 26. The textile of Aspect 25, wherein the thermoplasticelastomeric styrenic copolymer comprises a styrene butadiene styrene(SBS) block copolymer, a styrene ethylene/butylene styrene (SEBS)copolymer, a styrene acrylonitrile copolymer (SAN), or any combinationthereof.

Aspect 27. The textile of Aspect 25, wherein the thermoplasticelastomeric polyurethane comprises a thermoplastic elastomeric polyesterpolyurethane, a thermoplastic polyether polyurethane, or any combinationthereof.

Aspect 28. The textile of Aspect 27, wherein the thermoplasticelastomeric polyurethane comprises an aromatic polyester thermoplasticelastomeric polyurethane.

Aspect 29. The textile of any of Aspects 25-28, wherein thethermoplastic elastomeric polyurethane comprises an aliphatic polyesterthermoplastic elastomeric polyurethane.

Aspect 30. The textile of any of Aspects 1-29, wherein the textilefurther comprises a lubricating composition.

Aspect 31. The textile of Aspect 30, wherein the lubricating compositionis from about 0.1 weight percent to about 3 weight percent of thetextile.

Aspect 32. The textile of Aspect 30 or 31, wherein the lubricatingcomposition comprises mineral oil, silicone oil, or a combinationthereof.

Aspect 33. The textile of any of Aspects 1-32, wherein the first coatedyarn has a stress at break greater than 7 megapascals, optionallygreater than 8 megapascals, or greater than 8 megapascals as determinedusing ASTM DE-412 at 25 degrees C.

Aspect 34. The textile of any of Aspects 1-33, wherein the first coatedyarn has a tensile stress at 300 percent modulus greater than 2megapascals, optionally greater than 2.5 megapascals, or greater than 3megapascals as determined using ASTM DE-412 at 25 degrees C.

Aspect 35. The textile of any of Aspects 1-34, wherein the first coatedyarn has an elongation at break greater than 450 percent, optionallygreater than 500 percent, or greater than 550 percent as determinedusing the Yarn Modulus, Tenacity and Elongation Test.

Aspect 36. The textile of any of Aspects 1-35, wherein the first coatedyarn has a tenacity of about 1 gram per denier to about 10 grams perdenier as determined using the Yarn Modulus, Tenacity and ElongationTest.

Aspect 37. A textile, comprising:

a thermoformed network of yarns, the thermoformed network comprising afirst core yarn and a first polymeric composition, wherein the firstpolymeric composition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition.

Aspect 38. The textile of Aspect 37, wherein the thermoformed network ofyarns is the thermoformed product of a first textile comprising a firstnetwork of yarns including a first coated yarn comprising the first coreyarn and a first coating, the first coating including the firstpolymeric composition, wherein, in the thermoformed network, the firstpolymeric composition consolidating the thermoformed network of yarns isthe re-flowed and re-solidified product of the first polymericcomposition of the first coating of the first coated yarn.

Aspect 39. The textile of Aspect 37 or 38, wherein the thermoformednetwork of yarns is the thermoformed product of a textile according toany one of Aspects 1 to 36.

Aspect 40. The textile of any of Aspects 37 to 39, wherein, when thetextile has a mass loss of less than 0.05 weight percent after 300cycles as determined by the Akron Abrasion Test.

Aspect 41. The textile of any of Aspects 37 to 39, wherein the textilehas a mass loss of less than 0.20 weight percent after 3,000 cycles asdetermined by the Akron Abrasion Test.

Aspect 42. The textile of any of Aspects 37 to 41, wherein the textilepasses at least 1,200 cycles, or optionally at least 1,300 cycles, or atleast 1,600 cycles of the Stoll Abrasion Test.

Aspect 43. The textile of any of Aspects 37 to 42, wherein the textilepasses at least at least 75 cycles, or at least 100 cycles, or at least125 cycles of the Bally Flex Test.

Aspect 44. The textile of any of Aspects 37 to 43, wherein the textilepasses at least 3,000 cycles, or at least 5,000 cycles, or at least7,000 cycles of the Wet Bally Flex Test.

Aspect 45. The textile of any of Aspects 37 to 44, wherein the textileproduces a ball spin rate of at least 220 revolutions per minute, or aball spin rate of about 220 revolutions per minute to about 240revolutions per minute, as determined using the Textile-Ball ImpactTest.

Aspect 46. The textile of any of Aspects 37 to 45, wherein the firstpolymeric composition has an abrasion loss of less than 0.50 cubiccentimeters, optionally less than 0.40 cubic centimeters, less than 0.30cubic centimeters, less than 0.20 cubic centimeters, or less than 0.10cubic centimeters as determined using the Akron Abrasion Test.

Aspect 47. The textile of any of Aspects 37 to 46, wherein the firstpolymeric composition has an abrasion loss of less than 0.30 cubiccentimeters, less than 0.20 cubic centimeters, less than 0.10 cubiccentimeters, less than 0.05 cubic centimeters, or less than 0.30 cubiccentimeters, as determined using the DIN Abrasion Test.

Aspect 48. The textile of any of Aspects 37 to 47, wherein the firstpolymeric composition has a dry dynamic coefficient of friction of atleast 1.0 as determined against dry smooth concrete using the SampleCoefficient of Friction Test.

Aspect 49. The textile of any of Aspects 37 to 48, wherein the firstpolymeric composition has a wet dynamic coefficient of friction of atleast 0.5 as determined against wet smooth concrete using the SampleCoefficient of Friction Test.

Aspect 50. The textile of any of Aspects 37 to 49, wherein thedifference between the dry dynamic coefficient of friction and the wetcoefficient of the first polymeric composition as determine againstsmooth concrete is less than 40 percent, optionally less than 30percent, or less than 20 percent as determined using the SampleCoefficient of Friction Test.

Aspect 51. The textile of any of Aspects 37 to 50, wherein thethermoformed network of the textile has a dry dynamic coefficient offriction of at least 0.8 as determined against dry smooth concrete usingthe Sample Coefficient of Friction Test.

Aspect 52. The textile of any of Aspects 37 to 51, wherein the firstthermoformed network of the textile has a wet dynamic coefficient offriction of at least 0.5 as determined against wet smooth concrete usingthe Sample Coefficient of Friction Test.

Aspect 53. The textile of any of Aspects 37 to 52, wherein thedifference between the dry dynamic coefficient of friction and the wetcoefficient of the thermoformed network of the textile as determineagainst smooth concrete is less than 50 percent, optionally less than 40percent, or less than 30 percent as determined using the SampleCoefficient of Friction Test.

Aspect 54. The textile of any of Aspects 37 to 53, wherein thedifference between the static coefficient of friction of the dry surfaceand the wet surface of the textile is less than 40 percent, optionallyless than 30 percent, or less than 20 percent as determined using theSample Coefficient of Friction Test.

Aspect 55. The textile of any of Aspects 37 to 54, wherein thethermoformed network of the textile has a dry dynamic coefficient offriction of at least 1.0 as determined using the Textile-BallCoefficient of Friction Test.

Aspect 56. The textile of any of Aspects 37 to 55, wherein the firstthermoformed network of the textile has a wet dynamic coefficient offriction of at least 0.5 as determined using the Textile-BallCoefficient of Friction Test.

Aspect 57. The textile of any of Aspects 37 to 56, wherein thedifference between the dry dynamic coefficient of friction and the wetdynamic coefficient of friction is less than 40 percent, optionally lessthan 30 percent, or less than 20 percent as determined using theTextile-Ball Coefficient of Friction Test.

Aspect 58. The textile of any of Aspects 37 to 57, wherein thethermoformed network of the textile has a dry static coefficient offriction of at least 1.2 as determined using the Textile-BallCoefficient of Friction Test.

Aspect 59. The textile of any of Aspects 37 to 58, wherein thethermoformed network of the textile has a wet static coefficient offriction of at least 0.9 as determined using the Textile-BallCoefficient of Friction Test.

Aspect 60. The textile of any of Aspects 37 to 59, wherein thedifference between the dry static coefficient of friction and the wetstatic coefficient of friction of the thermoformed network of thetextile is less than 40 percent, optionally less than 30 percent, orless than 20 percent as determined using the Textile-Ball Coefficient ofFriction Test.

Aspect 61. An article comprising the textile according to any one ofAspects 1 to 60.

Aspect 62. The article of Aspect 61, wherein the article is a componentof an article of apparel, footwear, or sporting equipment, or is anarticle of apparel, footwear, or sporting equipment.

Aspect 63. An upper for an article of footwear, comprising:

a textile, wherein the textile comprises a first network of yarnsincluding a first coated yarn, the first coated yarn comprising a firstcore yarn and a first coating including a first polymeric compositiondisposed on at least a portion of an outer surface of the first coreyarn, wherein the first polymeric composition is a thermoplasticelastomeric composition.

Aspect 64. The upper of Aspect 63, wherein the textile defines at leasta portion of a surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear.

Aspect 65. The upper of Aspect 63, wherein the textile defines at leasta portion of the surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear, or defines atleast a portion of a surface of the upper configured to beinternally-facing when the upper is part of a finished article offootwear, or forms at least a portion of an interior layer of the upperwhen the upper is part of a finished article of footwear, or anycombination thereof.

Aspect 66. The upper of any of Aspects 63 to 65, wherein the textile isa textile according to any one of Aspects 1 to 36.

Aspect 67. An upper for an article of footwear, comprising:

a first textile comprising a thermoformed network of yarns comprising afirst core yarn and a first polymeric composition, wherein the firstpolymeric composition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition.

Aspect 68. The upper of Aspect 67, wherein the textile defines at leasta portion of a surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear.

Aspect 69. The upper of Aspect 67, wherein the textile defines at leasta portion of the surface of the upper configured to be externally-facingwhen the upper is part of a finished article of footwear, or defines atleast a portion of a surface of the upper configured to beinternally-facing when the upper is part of a finished article offootwear, or forms at least a portion of an interior layer of the upperwhen the upper is part of a finished article of footwear, or anycombination thereof.

Aspect 71. The upper of any of Aspects 67 to 70, wherein the textilecomprises the textile of any of Aspects 1 to 60.

Aspect 72. The upper of any of Aspects 67-71, wherein the textiledefines at least a portion of a surface of the upper configured to beexternally-facing when the upper is part of a finished article offootwear,

Aspect 73. The upper of any of Aspects 67-71, wherein the textiledefines from about 15 percent to about 100 percent, or from about 15percent to about 35 percent, or from about 40 percent to about 70percent, or from about 75 percent to about 100 percent of the totalsurface area of the upper configured to be externally-facing when theupper is part of a finished article of footwear.

Aspect 74. The upper of any of Aspects 67-73, wherein the thermoformednetwork of the thermoformed textile defines at least a portion of asurface of the upper configured to be externally-facing when the upperis part of a finished article of footwear,

Aspect 75. The upper of any of Aspects 67-74, wherein the thermoformednetwork includes an externally-facing side, the externally-facing sideof the thermoformed network defines at least a portion of the surface ofthe upper configured to be externally-facing when the upper is part of afinished article of footwear, and about 15 percent to 100 percent, orabout 15 percent to 35 percent, or about 40 percent to 70 percent, orabout 75 percent to 100 percent of a total surface area of theexternally-facing side of the thermoformed network comprises the firstpolymeric composition.

Aspect 76. The upper of any of Aspects 67-75, wherein the firstpolymeric composition comprises about 15 percent to 95 percent byweight, or about 15 percent to 35 percent by weight, or about 40 percentto 70 percent by weight, or about 75 percent to 95 percent by weight ofthe textile, based on a total weight of the textile present in theupper.

Aspect 77. The upper of any of Aspects 67-76, wherein the textileproduces a ball spin rate of at least 210 revolutions per minute, or aball spin rate of about 210 revolutions per minute to about 230revolutions per minute, as determined using the Upper-Ball Impact Test.

Aspect 78. An outsole for an article of footwear, comprising:

a textile comprising a thermoformed network of yarns comprising a firstcore yarn and a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition.

Aspect 79. The outsole of Aspect 78, wherein the thermoformed networkdefines at least a portion of an externally-facing surface of theoutsole, optionally wherein the externally-facing surface is configuredto be ground-facing or ground-contacting when the outsole is part of afinished article of footwear.

Aspect 80. The outsole of Aspect 78 or 79, wherein the thermoformedtextile defines at least a portion of a heel region, a toe region, or amidfoot region, or any combination thereof, of the outsole.

Aspect 81. The outsole of any of Aspects 78 to 80, wherein thethermoformed network of the textile, when new, has a dry dynamiccoefficient of friction of greater than 1.0 as determined against smoothconcrete using the Whole Footwear Coefficient of Friction Test.

Aspect 82. The outsole of any of Aspects 78 to 81, wherein thethermoformed network of the textile, when new, has a wet dynamiccoefficient of friction of greater than 0.5 as determined against smoothconcrete using the Whole Footwear Coefficient of Friction Test.

Aspect 83. The outsole of any of Aspects 78 to 82, wherein thedifference between the dry dynamic coefficient of friction and the wetdynamic coefficient of friction of the thermoformed network of thetextile, when new, is less than 40 percent, optionally less than 30percent, or less than 20 percent as determined against smooth concreteusing the Whole Footwear Coefficient of Friction Test.

Aspect 84. The outsole of any of Aspects 78 to 83, wherein thethermoformed network of the textile, after being abraded according tothe Whole Footwear Abrasion Test, has a dry dynamic coefficient offriction of greater than 0.9 as determined against smooth concrete usingthe Whole Footwear Coefficient of Friction Test.

Aspect 85. The outsole of any of Aspects 78 to 84, wherein thethermoformed network of the textile, after being abraded according tothe Whole Footwear Abrasion Test, has a wet dynamic coefficient offriction of greater than 0.5 as determined against smooth concrete usingthe Whole Footwear Coefficient of Friction Test.

Aspect 86. The outsole of any of Aspects 78 to 85, wherein thedifference between the dry dynamic coefficient of friction and the wetdynamic coefficient of friction of the thermoformed network of thetextile, after being abraded according to the Whole Footwear AbrasionTest, is less than 40 percent, optionally less than 30 percent, or lessthan 20 percent as determined against smooth concrete using the WholeFootwear Coefficient of Friction Test.

Aspect 87. The outsole of any of Aspects 78 to 86, wherein thethermoformed network defines at least a portion of a surface of theoutsole configured to be ground-contacting when the outsole is part of afinished article of footwear, and the thermoformed network furthercomprises a layer of a third polymeric composition, wherein the thirdpolymeric composition is a thermoplastic elastomeric compositioncomprising a thermoplastic elastomeric styrenic copolymer; wherein afirst side of the layer defines the surface of the outsole configured tobe ground-contacting when the outsole is part of a finished article offootwear, and a second side of the yarn opposite the first side isthermally bonded to a first side of the textile via the first polymericcomposition of the textile.

Aspect 88. The outsole of Aspect 87, wherein the layer of the thirdpolymeric composition is an extruded layer or an injection molded layeror a film layer.

Aspect 89. The outsole of Aspect 87 or 88, wherein the thermoplasticelastomeric styrenic copolymer of the first polymeric composition andthe thermoplastic elastomeric styrenic copolymer of the third polymericcomponent each have the same chemical structure, or the first polymericcomposition and the third polymeric composition each have meltingtemperatures within about 10 degrees C. of each other, or both.

Aspect 90. The outsole of any of Aspects 87-89, wherein the layer of thethird polymeric composition has a thickness of from about 0.1 millimeterto about 5 millimeters.

Aspect 91. The outsole of any of Aspects 78-90, wherein the textilecomprises the textile of any of Aspects 1 to 60.

Aspect 92. A method of making a textile, the method comprising:

forming a first network of yarns including a first coated yarn, thefirst coated yarn comprising a first core yarn and a first coatingincluding a first polymeric composition disposed on at least a portionof an outer surface of the first core yarn, wherein the first polymericcomposition is a thermoplastic elastomeric composition.

Aspect 93. The method of Aspect 92, wherein the textile is a textileaccording to any one of Aspects 1-36.

Aspect 94. A method of making a textile, the method comprising:

thermoforming a first textile comprising a first network of yarnsincluding a first coated yarn, the first coated yarn comprising a firstcore yarn and a first coating including a first polymeric compositiondisposed on at least a portion of an outer surface of the first coreyarn, wherein the first polymeric composition is a thermoplasticelastomeric composition; thereby forming a thermoformed network of yarnscomprising the first core yarn and the first polymeric composition,wherein the first polymeric composition consolidates the thermoformednetwork of yarns by surrounding at least a portion of the first coreyarn and occupying at least a portion of spaces between yarns in thethermoformed network of yarns.

Aspect 95. The method of Aspect 94, wherein the first textile is atextile according to any one of Aspects 1 to 60.

Aspect 96. A textile made according to any one of Aspects 92 to 95.

Aspect 97. A method of making an upper for an article of footwear, themethod comprising:

affixing a first textile to a second component, wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition.

Aspect 98. A method of making an upper for an article of footwear, themethod comprising:

thermoforming an upper comprising a first textile, wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition; andwherein the thermoforming comprises melting, reflowing, andre-solidifying the first polymeric composition within the first textile,forming a thermoformed textile comprising a thermoformed network ofyarns comprising the first core yarn and the first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns.

Aspect 99. A method of making an upper for an article of footwear, themethod comprising:

affixing a first textile to a second component, wherein the firsttextile comprises a thermoformed network of yarns comprising a firstcore yarn and a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition.

Aspect 100. The method of any of Aspects 97 to 99, wherein the firsttextile is a textile according to any one of Aspects 1 to 60.

Aspect 101. An upper made according to the method of any one of Aspects97 to 100.

Aspect 102. A method for making an outsole for an article of footwear,the method comprising thermoforming a first textile; wherein thethermoforming comprises thermoforming the textile on a sole component,or on a molding surface, optionally wherein the molding surface is amolding surface having the dimensions of the outsole; wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition; andwherein the thermoforming comprises melting, reflowing, andre-solidifying the first polymeric composition within the first textile,forming a thermoformed textile comprising a thermoformed network ofyarns comprising the first core yarn and the first polymericcomposition, wherein the first polymeric composition consolidates thethermoformed network of yarns by surrounding at least a portion of thefirst core yarn and occupying at least a portion of spaces between yarnsin the thermoformed network of yarns.

Aspect 103. The method of Aspect 102, wherein the first textile has afirst side and a second side, wherein the method further comprisesthermally bonding a layer comprising a third polymeric composition tothe first side or the second side of the first textile, wherein thethird polymeric composition of the layer defines a surface of theoutsole configured to be externally-facing or ground-facing orground-contacting when the outsole is in a finished article of footwear.

Aspect 104. The method of Aspect 103, wherein the method comprisesthermally bonding a sheet comprising the third polymeric composition tothe first textile before, during or after the step of thermoforming thefirst textile.

Aspect 105. The method of Aspect 103, wherein the method comprisesextruding or injection molding the third polymeric composition on thefirst side or the second side of the first textile before, during orafter thermoforming the first textile.

Aspect 106. The method of any one of Aspects 102-105, wherein the firsttextile is a textile according to any one of Aspects 1 to 60.

Aspect 107. An outsole made according to the method of any one ofAspects 102 to 106.

Aspect 108. A method of making an article, comprising:

affixing a first textile to a second component, wherein the firsttextile comprises a first network of yarns including a first coatedyarn, the first coated yarn comprising a first core yarn and a firstcoating including a first polymeric composition disposed on at least aportion of an outer surface of the first core yarn, wherein the firstpolymeric composition is a thermoplastic elastomeric composition.

Aspect 109. A method of making an article, the method comprising:

thermoforming a first textile, wherein the first textile comprises afirst network of yarns including a first coated yarn, the first coatedyarn comprising a first core yarn and a first coating including a firstpolymeric composition disposed on at least a portion of an outer surfaceof the first core yarn, wherein the first polymeric composition is athermoplastic elastomeric composition; and wherein the thermoformingcomprises melting, reflowing, and re-solidifying the first polymericcomposition within the first textile, forming a thermoformed textilecomprising a thermoformed network of yarns comprising the first coreyarn and the first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns,

Aspect 110. A method of making an article, the method comprising:

affixing a first textile to a second component, wherein the firsttextile comprises a thermoformed network of yarns comprising a firstcore yarn and a first polymeric composition, wherein the first polymericcomposition consolidates the thermoformed network of yarns bysurrounding at least a portion of the first core yarn and occupying atleast a portion of spaces between yarns in the thermoformed network ofyarns, and wherein the first polymeric composition is a thermoplasticelastomeric composition; optionally wherein the article is a componentof an article of footwear, apparel or sporting equipment, or is anarticle of footwear, apparel or sporting equipment.

Aspect 111. The method of any one of Aspects 108 to 110, wherein thefirst textile is a textile according to any one of Aspects 1 to 60.

Aspect 112. An article made by the method of any one of Aspects 108 to111.

From the foregoing, it will be seen that aspects herein are well adaptedto attain all the ends and objects hereinabove set forth together withother advantages which are obvious and which are inherent to thestructure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

Since many possible aspects may be made without departing from the scopethereof, it is to be understood that all matter herein set forth orshown in the accompanying drawings is to be interpreted as illustrativeand not in a limiting sense.

While specific elements and steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinis contemplated as being combinable with any other elements and/or stepsregardless of explicit provision of the same while still being withinthe scope provided herein. Since many possible aspects may be made ofthe disclosure without departing from the scope thereof, it is to beunderstood that all matter herein set forth or shown in the accompanyingdrawings is to be interpreted as illustrative and not in a limitingsense.

EXAMPLES

The present disclosure is more particularly described in the followingexamples that are intended as illustrations only, since numerousmodifications and variations within the scope of the present disclosurewill be apparent to those skilled in the art.

Polymer Screening

Thermoplastic polyurethane elastomers and thermoplastic styreniccopolymer elastomers were evaluated as candidates for the preparation ofcoated yarns, textiles and other articles as described herein. Severalproperties were determined for each polymer, and the results aresummarized in Tables 1 and 2. The hardness of the polymers wasdetermined using the Durometer Hardness Test, the specific gravity wasdetermined using the Specific Gravity Test, the DIN abrasion loss wasdetermined using the DIN Abrasion Test, and the coefficients of frictionwere determined using the Sample Coefficient of Friction Test asdisclosed herein.

TABLE 1 DIN abrasion Polymer Durometer Specific mass loss Material Gradetype Supplier (Shore A) Gravity (milligrams) Monprene 66070 SEBS TPETeknor 76 A 0.897 374 Apex Ellastolan SP9339 TPU BASF 0.7944 Estane58238 TPU Lubrizol 75 A 1.17 65 Estane T470A-3 TPU Lubrizol 77 A 1.14 74

TABLE 2 Smooth Rough Rough Percent Percent Smooth Dry Wet Dry WetDifference Difference Concrete concrete Concrete Concrete (Dry- (Dry-(Dynamic (Dynamic (Dynamic (Dynamic Wet)/Dry Wet)/Dry Material GradeCOF) COF) COF) COF) Smooth Rough Monprene 66070 1.211 0.873 0.830 0.71772 28 Ellastolan SP9339 1.434 0.629 1.091 0.652 44 56 Estane 58238 1.0390.483 0.835 0.450 46 54 Estane T470A-3 1.055 0.463 0.873 0.537 44 56

Properties of Coated Yarns

Coated yarns coated with polymeric compositions including polymers underinvestigation were made and their properties were investigated. Acomparison of hardness values, glass transition temperature, meltingtemperature, tensile strength, and elongation at break is provided inTable 3, where the hardness of the polymer was determined using theDurometer Hardness Test, the glass transition temperatures and themelting temperatures of the polymers were determined using the Meltingand Glass Transition Temperature Test, and the yarn tensile strength andelongation were determined using the Yarn Modulus, Tenacity, andElongation Test disclosed herein:

TABLE 3 Properties of Control and Test Coated Yarns Glass TransitionMelting Tensile Elongation Yarn Polymer Polymer Durometer Temp. (degreesTemp. (degrees Strength at Break Sample Supplier Grade (Shore A)Celsius) Celsius) (Megapascals) (percent) WC1 Lubrizol Estane 75 ± 3 −68150 48.3 680 58238 WC2 Lubrizol Estane 77 ± 3 −50 150 28 840 T470A-3Hard Lubrizol Esdex 92 ± 3 −39 150 62 480 TPU 219UN

Differential scanning calorimetry studies to evaluate melting andrecrystallization behavior of polymers under investigation for use ascoatings for yarn were conducted according to the Melting and GlassTransition Temperature Test described herein. Results are presented inTable 4:

TABLE 4 Polymer Melting and Cooling Data Melting Behavior PeakRecrystallization Behavior (Cooling after Melting) Melting Onset ofMelting Onset of Peak Enthalpy Tem. Melting Temp. EnthalpyCrystalization Crystalization (Joules Polymer Polyol (degrees (degrees(degrees (Joules (degrees (degrees per DSC Data Type Type Celsius)Celsius) Celsius) per gram) Celsius) Celsius) gram) Estane 58238 TPUAromatic  −44 134.79 149.31 7.4591 69.6 48.2 4.1687 Polyester EstaneT470A-3 TPU Polyester  −49 134.5 155.05 9.9512 100.47 85.6 7.3121Monprene SP66070 SEBS N/A <−35 150.39 164.25 22.057 113.5 104.21 20.677Monprene SP16074H SEBS N/A <−35 144.87 159.65 23.482 110.97 107.1 24.995Monprene IN15074 SEBS N/A <−35 145.13 160.33 21.563 110.54 103.78 23.006

Rheology data for molten polymers was collected according to the MoltenPolymer Viscosity Test described herein. Results are presented in Table5:

TABLE 5 Molten Polymer Rheology Data Viscosity at 1 Viscosity at 10Viscosity at 100 Reciprocal Second Reciprocal Seconds Reciprocal SecondsMaterial (Pascal · seconds) (Pascal · seconds) (Pascal · seconds) Estane58238 690 640 465 Estane T470A-3 545 525 400 Monprene SP 66070 170 170145 Monprene SP 16074H 20500 3000 550 Monprene SP 15074 22900 5300 1150

These results indicate that Estane 58238, Estane T470A-3, and MonpreneSP66070 are particularly well-suited for high flow rate extrusion onfast moving fibers (e.g. core yarn).

Solid state tensile properties for the polymers useful as yarn coatingcompositions are presented in Table 6, as determined using the PlaqueModulus Test described herein:

TABLE 6 Solid State Tensile Properties Break Strain to Load at 100Material Polymer Strength Break Percent Strain Toughness Tear Grade Type(kg · f) (Percent) (kg · f/mm) (kg ·× mm) Stiffness Strength Rubber ARubber 14.0 709 3.2 927 37.9 35 Estane TPU 34.2 792 3.8 2176 63.8 78.858238 Estane TPU 30.5 690 4.7 1737 84.3 76.6 T470A-3 Monprene SEBS 13.3717 5.0 1495 102.9 60.9 SP 66070 Monprene SEBS 10.1 450 7.7 865 154.149.9 IN 15074

Traction and Abrasion Losses of Plaques

2 millimeter thick plaques of material were used to test for tractionand abrasion properties. Plaques were tested according to the SampleCoefficient of Friction Test described herein.

Cross-linked rubber materials are known to exhibit reduced material ormass loss during abrasion testing, while thermoplastic materials havetypically not been able to match the balance of traction and abrasionloss provided by cross-linked rubbers. However, the polymers testedshowed good traction performance relative to known rubber outsoleformulations. Results obtained in accordance with the Durometer HardnessTest, the Specific Gravity Test, the DIN Abrasion Test, and the SampleCoefficient of Friction Test described herein can be seen in Tables 7.Table 8 presents the results of whole shoe tests using outsolescomprising thermoformed textiles as described herein, obtained inaccordance with the Whole Footwear Coefficient of Friction Test and theWhole Footwear Abrasion Test disclosed herein. Table 9 shows hardnessand Akron abrasion loss results for thermoformed textiles describedherein when used as outsoles, as obtained using the Durometer HardnessTest and the Akron Abrasion Test as disclosed herein.

TABLE 7 Dry and Wet Coefficient of Friction for 2 Millimeter FlatPlaques 2 mm Flat Plaque Geometry DIN Smooth Dry Concrete Smooth WetConcrete Polymer and Rubber Comparisons Abrasion 3 × 3 × MaterialPolymer Durometer Specific Mass Loss Dynamic Standard Dynamic StandardGrade Type Form Supplier (Shore A) Gravity (mg) COF Deviation COFDeviation Rubber A Rubber Solid N/A 67-70 1.16 70 1.305 0.050 0.4700.030 Rubber B Rubber Solid N/A 66-68 1.07 57 1.592 0.037 0.341 0.020Estane T470A-3 TPU Solid Lubrizol 77 1.14 74 1.055 0.017 0.463 0.010Estane 58238 TPU Solid Lubrizol 75 1.17 65 1.039 0.012 0.483 0.044Monprene SEBS TPE Solid Teknor Apex 76 0.89 374 1.211 0.024 0.873 0.022SP66070 Monprene SEBS TPE Solid Teknor Apex 75 0.89 66 1.235 0.030 0.4700.020 IN15074

Whole Footwear Outsole Abrasion and Coefficient of Friction TestingPolymer and Rubber Comparisons Whole Footwear Footwear Traction AbrasionMass Loss Abrasion Footwear Traction (Before Abrasion) (After Abrasion)(Grams) at 96 Hours, Dry Wet Dry Wet 180 Pound Load, 1 Concrete ConcreteConcrete Concrete Type Strike/Second COF COF COF COF TPU 1.6 1.03 0.650.92 0.58 TPU 1.4 1.08 0.53 0.91 0.56 SEBS 2.2 1.05 0.63 1.12 0.64

TABLE 9 Hardness and Abrasion Loss for Thermoformed Outsoles PolymerDensity Polymer Polymer Akron Polymer (grams COF Dry COF Wet PolymerAbrasion Akron Durometer per cubic Concrete Concrete DIN (cubic AbrasionSample Name Polymer Type Usage (Shore A) centimeter) Smooth SmoothAbrasion centimeters) (grams) Rubber A Butadiene Outsole 66 1.15 1.3050.470 70 0.248 0.29 synthetic rubber rubber blend Rubber B PeroxideOutsole 66 1.08 1.592 0/341 57 0.2 0.22 cured rubber rubber blend WC2 -Plaque TPU Estane Polymer test 72 1.13 1.055 0.463 74 T470A-3 plaqueWC1 - Plaque TPU Estane Polymer test 70 1.17 1.039 0.483 65 58238 plaqueWC3 - Plaque TPE - Polymer test 70 0.9 1.211 0.873 374 Monprene plaqueSP066070 WC2 - Fused TPU Estane 0.4 millimeter 72 1.52 0.51 0.13 KnitT470A-3 yarn in knit WC1 - Fused TPU Estane 0.4 millimeter 70 0.85 0.520.06 Knit 58238 yarn in knit WC3 - Fused TPE - 0.4 millimeter 70 1.060.52 0.32 Knit Monprene yarn in knit SP066070

Yarn candidate coatings are abbreviated herein and in Tables 8 and 9 asfollows with respect to coated yarns: WC1=coated with or plaque formedfrom Estane 58238 TPU, WC2=coated with or plaque formed from EstaneT470A-3 TPU, WC3=coated with or plaque formed from Monprene SP66070 TPE.

Solid polymers and corresponding coated yarns were tested for abrasionmass loss and traction using the Akron Abrasion Test and the SampleCoefficient of Friciton Test as described herein. Traction properties ofthe thermoformed knit textiles were comparable to polymer test plaquesand to rubber outsole materials, indicating that the thermoformed knittextiles were successfully thermoformed to form thermoformed networks(Table 9). Additionally, Akron abrasion material losses measured for thethermoformed knit textiles were comparable to the rubber controlreferences. Mass loss measured for Akron abrasion test strips 0.5 incheswide and 8 inches long were comparable to much larger outsole areas ofwhole shoe mass as described in Table 8. Thus, test strips and wholeshoe performance are consistent and thermoformed knit textiles wereshown to be acceptable as outsole materials as they did not losematerial out of scale with representative rubbers and further, thethermoformed knit textiles exhibited sufficient traction properties toperform as outsoles.

Evaluation of Coated Yarns

Two sample types of coated yarns were prepared into flat knit textileswatches. The first swatch used UNIFI polyethylene terephthalate(polyester) yarn (158 denier, tenacity of 7.131 grams per denier, 23.42percent elongation) as the core yarn, and was coated with a polymericcomposition consisting essentially of Estane 58238 at a thickness ofabout 0.4 millimeters. The second swatch used the same UNIFIpolyethylene terephthalate yarn core yarn, but was coated with apolymeric composition consisting essentially of Monprene TPE SP66070 ata thickness of about 0.4 millimeters. The flat knit textile swatcheswere thermoformed either without texture or with a herringbone textureprior to testing.

There are two versions knit for each type of coated yarn: single yarnend edge-2 knit structures (1×1) and two yarn end edge-2 knit structures(1×2) that have one end of yarn on the surface of the thermoformednetwork of the thermoformed textile, or two ends of yarn (for a greaterconcentration of the polymeric coating) at the surface of thethermoformed network, respectively. The knit structure of the swatchesalso included an end of the uncoated UNIFI PET yarn. The description ofthe knit structures, i.e., (1×1) and (1×2), identifies the number ofends of yarn used, where the first number corresponds to the number ofuncoated polyester yarns present and the second number corresponds tothe number of coated yarns present. The edge-2 knit structure is adouble-bed knit structure with tuck knit stitches connecting the twofaces of the knit textile. One face of the textile is exclusivelyuncoated polyester yarn and the other is exclusively the coated yarnunder evaluation, with the tuck stitches connecting the two exteriorfacing knit surfaces. Tuck stitches are constructed from the same coatedyarns as the outer face yarn.

All samples were tested for Akron abrasion in accordance with the AkronAbrasion Test, and wet/dry traction COF testing according to the SampleCoefficient of Friction test on court and concrete. The results areprovided in Tables 10 and 11.

Overall, the thermoformed textiles knitted from the coated yarn with acoating consisting essentially of the SEBS-based Monprene demonstrated ahigh dynamic coefficient of friction on concrete and court (Table 10).The thermoformed textiles including the Monprene coated yarndemonstrated higher coefficients of friction when thermoformed flat onsmooth concrete and court. The thermoformed textiles including theMonprene coated yarn demonstrated good coefficients of friction whentested dry and when wet.

The thermoformed textiles knitted from the coated yarn with a coatingconsisting essentially of the Estane demonstrated higher coefficients offriction when thermoformed flat and tested on smooth concrete and court;the herringbone texture demonstrated a greater coefficient of frictionwhen tested on rough concrete. (Table 10). The thermoformed textilesincluding the Estane coated yarn demonstrated a good coefficient offriction when tested dry and wet (with some exceptions).

Overall, the thermoformed 1×2 knit textiles exhibited less volumetricloss on abrasion testing than the thermoformed 1×1 knit textiles. Thethermoformed textiles including the Estane coated yarn exhibited lessvolumetric loss than the thermoformed textiles including the Monprenecoated yarn.

TABLE 10 Traction Results Dry Wet Dry Wet Outsole Smooth Smooth Dry WetRough Rough Texture Concrete Concrete Court Court Concrete ConcreteMonprene Not Textured 1.06 ± 0.32 0.52 ± 0.21 0.96 ± 0.12 0.49 ± 0.780.88 ± 0.15 0.51 ± 0.07 Coated Yarn, Herringbone 0.96 ± 0.25 0.50 ± 0.310.63 ± 0.02 0.35 ± 0.40 0.78 ± 0.21 0.57 ± 0.04 1 × 1 knit TextureMonprene Not Textured 1.06 ± 0.32 0.50 ± 0.04 1.04 ± 0.13 0.42 ± 0.540.82 ± 0.23 0.51 ± 0.02 Coated Yarn, Herringbone 0.98 ± 0.38 0.53 ± 0.290.46 ± 0.08 0.36 ± 0.26 0.89 ± 0.12 0.54 ± 0.08 1 × 2 knit TextureEstane Not Textured 0.85 ± 0.15 0.53 ± 0.12 1.01 ± 0.15 0.39 ± 0.36 0.51± 0.25 0.35 ± 0.02 Coated Yarn, Herringbone 1.02 ± 0.12 0.46 ± 0.28 0.38± 0.21 0.23 ± 0.21 0.78 ± 0.11 0.32 ± 0.04 1 × 1 knit Texture Estane NotTextured 0.72 ± 0.36 0.43 ± 0.07 0.95 ± 0.04 0.91 ± 0.04 0.44 ± 0.110.34 ± 0.02 Coated Yarn, Herringbone 0.76 ± 0.14 0.47 ± 0.31 0.55 ± 0.320.57 ± 0.32 0.67 ± 0.14 0.34 ± 0.02 1 × 2 knit Texture Typical Nike NotTextured 1.35 ± 0.05 0.47 ± 0.03 1.25 ± 0.17 0.44 ± 0.1  0.945 ± 0.02 0.455 ± 0.03  rubber outsole formulation

TABLE 11 Abrasion Resistance Results Mass Mass Abrasion Mass after 300after 3000 Resistance Average before cycle (+300) (cubic ThermoformedSpecific testing break-in cycles centimeter Sample Texture Gravity(grams) (grams) (grams) loss) Monprene Flat 0.815 40.5613 40.517240.1456 0.456 Coated Yarn, 1 × 1 knit Monprene Flat 0.800 41.0536 41.01540.695 0.400 Coated Yarn, 1 × 2 knit Estane Flat 0.939 42.9179 42.910742.8502 0.064 Coated Yarn, 1 × 1 knit Estane Flat 0.895 43.7073 43.693443.658 0.040 Coated Yarn, 1 × 2 knit Estane Flat 0.895 43.7073 43.693443.658 0.040 Coated Yarn, 1 × 2 knit

Textile and Article Thermoforming Processes

Coated and uncoated yarns were knit into edge-2 1×2 or 1×1 swatches andlightly pressed in a t-shirt press at 20 pounds per square inch and 150degrees Celsius for 20 seconds to avoid fraying. The swatches were cutinto outsole shapes and placed into a rubber-phylon mold having thecavity size of a standard rubber mold but coated for heating and coolingcycles similar to a phylon mold. The empty mold was preheated to themelting temperature of the polymer plus 15 degrees Celsius as measuredby a thermocouple. The cut outsole shapes were placed into the mold withuncoated polyester yarn side up and pressed for 45 seconds, then cooledfor at least 60 seconds, or 90 seconds if time allowed. In some cases,the edge-2 1×1 swatches were not large enough material to fill the mold.When the swatches were not large enough to fill the mold, silicone,rubber, or other material was added to fill the mold. Testedtemperatures, polymers present in the yarn coating, and times areprovided in Table 12:

TABLE 12 Thermoforming Processing Conditions Melting ProcessingTemperature Temperature (degrees (degrees Material Grade Celsius)Celsius) Monprene 66070 160 175 Estane 58238 130 145 Estane T470A-3 150165

When a regular thermoforming process was used, this was conducted on aDMT Press with a total heating time of 35 to 45 seconds and a pressureof 30 bar. The process was stopped when the thermocouple reached 130degrees Celsius or 150 degrees Celsius depending on the end point.

When a flat molding process was used, this was conducted on a Kukdongheat press with a total heating time of from 30 seconds to 60 seconds oruntil the textile reached 150 degrees Celsius as measured bythermocouple. Temperature was held for 0 to 10 seconds as needed. Theheating pressure was 0.1 megapascals and the heat press set point was190 degrees Celsius. Heating was stopped when the thermocouple reached150 degrees Celsius, with some samples receiving an additional dwelltime of 10 seconds as indicated. Cold pressing at 20 degrees Celsius wasthen carried out at 0.1 megapascals for 30 seconds.

When infrared (IR) heating and/or thermoforming was used, coated yarnswere knitted into an exemplary upper and the upper was placed in a FlashActivator with the surface of the upper to be heated facing the heatingelements. In some experiments, the surface of a knit upper configured tobe externally-facing was placed facing the heating elements, while inother experiments, the surface of the knit upper configured to beinternally-facing was placed facing the heating elements. However, theknit textile can be laid flat, heated, and then formed, or heated on alast in three dimensions and formed. The knit textile was exposed to IRflash heat for about 23 seconds, which was sufficient for the localtemperature of the irradiated surface to reach 160 degrees Celsius ormore. The upper and last were then removed from the Flash Activator andtemperature was measured with a heat gun while moving the upper to avacuum machine in order to verify the temperature was greater than themelting point of the polymeric composition of the yarn coating. The knitupper was then positioned on a vacuum stage so that the newlythermoformed surface of the textile of the upper contacted the desiredtemplate master pattern for forming. A textured embossing pad (rubber,plastic, or silicone) was placed face down on the thermoformed surfaceof the upper such that the thermoformed surface is in contact with thesilicone pad molding pattern. The embossing pad can be at roomtemperature or heated to 120 to 200 degrees Celsius depending on thelength of time needed to maintain a higher temperature on the moltenpolymeric composition of the coating. The embossing pad and knit textileof the upper were pressed in a vacuum machine for 60 seconds. The vacuumwas released and discharged to reveal the surface of the thermoformednetwork of the thermoformed knit textile.

Abrasion Resistance of Textiles

Shown in Table 13 are abrasion mass losses for unthermoformed knittextiles and thermoformed knit textiles which were thermoformed in aflat configuration as determined after 300 and 3000 cycles of abrasiontesting using the Akron Abrasion Test. The knit textiles were knit usingthe UNIFI polyester core yarn described above coated with a polymericcomposition comprising a thermoplastic styrene copolymer elastomer(Monprene 66070) or a thermoplastic polyurethane elastomer (Estane58238). The knit structure of the knit textile included either 1 end(1×1) or 2 ends (1×2) of the coated yarn and 1 end of the uncoated UNIFIpolyester yarn knit on the surface of the knit textile which was tested.The knit structures are those described above.

TABLE 13 Akron Abrasion Loss at 300 Cycles and 3000 Cycles forThermoformed and Unthermoformed Knit Textiles Mass at Mass Loss at MassLoss at Mass Loss at Sample Test Initial Mass 300 Cycles 300 Cycles 3000Cycles 3000 Cycles Material Form and Structure (grams) (grams)(milligrams) (grams) (milligrams) Rubber A Flat Sheet Rubber 48.40048.3461 53.7 48.0663 334 Monprene Knit 40.741 40.7395 1.9 40.5382 20366070 Unthermoformed 1 × 1 Flat Thermoformed 40.561 40.5172 44.1 40.1456416 Knit Structure Knit Monprene Knit, 41.537 41.5271 9.4 41.3315 20566070 Unthermoformed 1 × 2 Flat Thermoformed 41.054 41.015 38.6 40.695359 Knit Structure Knit Estane Knit, 42.177 42.1746 2.8 41.6774 50058238 Unthermoformed 1 × 1 Flat Thermofomed 42.918 42.9107 7.2 42.850268 Knit Structure Knit Estane Knit, 44.510 44.5051 4.9 44.3383 172 58238Unthermoformed 1 × 2 Flat Thermoformed 43.707 43.6934 13.9 43.658 49Knit Structure Knit

The thermoformed knit textiles showed performance equal to or superiorto conventional rubber, and showed similar performance regardless ofwhether 1 or 2 ends were used at the top knit surface.

Durability and Weatherization

Durability and weatherization were assessed as a function of knitstructure and processing conditions using the Stoll Abrasion Test, BallyFlex Test, Wet Bally Flex Test, and Water Resistance Test as describedherein. A knit textile was produced using yarns coated with a polymericcomposition comprising a thermoplastic elastomer (Estane T470A-3) (WC2yarns), and thermoformed by heating in a press manufactured by KukdongMachinery (Busan, Korea) under flat molding conditions to 150 degreesCelsius. For some samples, the textile was held in the press for anadditional 10 seconds of dwell time after reaching the temperature of150 degrees Celsius. “Knit A” samples were knit samples having a knitstructure in which, when thermoformed, 75-100 percent of the totalsurface area of the thermoformed network was defined by the re-flowedand re-solidified polymeric composition. “Knit B” samples were knitsamples having a knit structure in which, when thermoformed, 40-70percent of the total surface area of the thermoformed network wasdefined by the re-flowed and re-solidified polymeric composition. “KnitC” samples were knit samples having a knit structure in which, whenthermoformed, 15-35 percent of the total surface area of thethermoformed network was defined by the re-flowed and re-solidifiedpolymeric composition. Performance of the Wet Bally Flex Test and WaterResistance Test were performed on textile samples having at least 90percent of their surface area covered by thermoformed network in orderto minimize water transmission through the sample.

TABLE 14 Durability and Weatherization as a Function of Knit Structureand Processing Thermoformed Stoll Bally Wet Bally Water Knit SamplesAbrasion Flex Flex Resistance Knit A 2500 100 Knit A with 10 2500 10015000 80 Second Dwell Knit B 1200 100 Knit B with 10 2200 100 SecondDwell Knit C 600 100

Textile-to-Ball and Upper-to-Ball Interactions

Thermoformed textiles and uppers for articles of footwear including thethermoformed textiles were manufactured, where the region of the textileor upper tested included a thermoformed network comprising a polymericas disclosed herein. “Knit A”, “Knit B”, and “Knit C” are as describedabove.

from the knit textiles were knit using coated yarns, wherein the coatingincluded a polymeric composition comprising a thermoplastic polyurethaneelastomer (Estane T470A-3). The coated yarn included a 0.4 millimetercoating of the polymeric composition on a 150-600 denier multifilamentpolyester yarn. Dry and wet coefficients of friction are presented inTable 15:

TABLE 15 Dry and Wet Static and Dynamic Coefficients of Friction (COF)for Thermoformed Knit Textiles Dry Wet Drop Average Average AverageAverage in COF Sample Textile Static Standard Dynamic Static StandardDynamic When Type COF Deviation COF COF Deviation COF Wet Duragon(Polyurethane 1.35 0.04 1.15 0.86 0.04 0.57 −36% Laminated Skin onPolyester Textile) Thermoformed Knit A 1.55 0.07 1.46 1.15 0.04 0.76−26% (Knit from Estane T470A-3 coated yarn) Thermoformed Knit B 1.420.11 1.22 0.94 0.06 0.51 −34% (Knit from Estane T470A-3 coated yarnThermoformed Knit C 1.21 0.07 0.97 0.91 0.04 0.54 −25% (Knit from EstaneT470A-3 coated yarn)

Thermoformed knit samples showed similar dry and wet coefficients offriction (e.g., boot-to-ball interaction) as the laminated Duragon skin.but in a streamlined, more integrated, lower waste manner ofconstruction.

Kangaroo leather displays little change between wet COF and dry COF, butboth wet and dry COF are low for this material overall. DURAGON skindisplays higher wet COF and dry COF but also a large difference betweenthese two values. Thermoformed textiles and/or footwear upperscontaining the coated yarns disclosed herein exhibit higher wet and dryCOF values overall, and a lower degree of difference between dry COF andwet COF than DURAGON skin.

Samples of knit textiles “Knit A”, “Knit B”, and “Knit C” thermoformedat 150 degrees C. as described above were tested using the Ball Speedand Spin After Textile-Ball Impact Test described above. Control samplesof Duragon polyurethane film laminated on a PET knit and kangarooleather were subjected to the same test.

TABLE 16 Material Effect on Soccer Ball Spin Rate Ball Spin Rate(revolutions per Standard Sample minute) Deviation Duragon Film 226.510.0 Thermoformed Knit C (Knit with 229.0 7.0 Estane T470A-3 coatedyarn) Thermoformed Knit B (Knit with 229.0 4.0 Estane T470A-3 coatedyarn) Thermoformed Knit A (Knit 236.0 8.0 withEstane T470A-3 coatedyarn) Kangaroo Leather 223.0 7.0

Uppers for full soccer boots were constructed from the yarns coated witha polymeric composition comprising a thermoplastic polyurethaneelastomer (either Estane 58238 or Estane T470A-3), thermoformed underdifferent processing conditions, and tested using the Ball Speed andSpin After Upper-Ball Impact Test described above. Results are presentedin Table 17:

TABLE 17 Full Lasted Boot Kick Test on Ball Average Ball Spin TextileThermoforming Type of Rate (revolutions Standard Description ConditionsBoot per minute) Deviation Textile + Duragon N/A Commercially 204 7Polyurethane available Laminate Skin Upper A (Knit with 130 degrees Test218 7 Estane 58238 Celsius Coated Yarn) Upper B (Knit with 150 degreesTest 217 6 Estane 58238 Celsius Coated Yarn) Upper C (Knit with 170degrees Test 212 9 Estane 58238 Celsius Coated Yarn) Upper D (Knit with130 degrees Test 219 6 Estane T470A-3 Celsius Coated Yarn) Upper E (Knitwith 150 degrees Test 212 9 Estane T470A-3 Celsius Coated Yarn) Upper F(Knit with 170 degrees Test 212 8 Estane T470A-3 Celsius Coated Yarn)Upper G (Knit with 170 degrees Comparative 205 7 90 Shore A TPU Celsiustest Coated Yarn)

These results indicate the 90 Shore A TPU made into coated yarn to forma knit and thermoformed upper showed lower spin rates, which is lessdesirable. Harder materials (as indicated by Shore A Durometer values)are more abrasion resistant.

Each of the thermoformed uppers knit with yarns coated with athermoplastic composition comprising a thermoplastic polyurethaneelastomer having a durometer of about 65 to 85 Shore A created higherlevels of ball spin. as compared to thermoformed knit uppers knit usinga yarn coated with a thermoplastic composition comprising athermoplastic polyurethane elastomer having a durometer of about 90Shore A, and commercially available uppers formed of DURAGON skin.

What is claimed is:
 1. An outsole for an article of footwear,comprising: a textile comprising a thermoformed network of yarnscomprising a first core yarn and a first polymeric composition, whereinthe first polymeric composition consolidates the thermoformed network ofyarns by surrounding at least a portion of the first core yarn andoccupying at least a portion of spaces between yarns in the thermoformednetwork of yarns, and wherein the first polymeric composition comprisesa thermoplastic elastomeric polyurethane, wherein the first polymericcomposition has a Durometer Hardness of from about 70 to about 80 ShoreA, as determined using the Durometer Hardness Test; wherein thethermoformed network of yarns is the thermoformed product of a firsttextile comprising a first network of yarns including a first coatedyarn comprising the first core yarn and a first coating, the firstcoating comprising the first polymeric composition, the first core yarncomprising a second polymeric composition, wherein the first coating isaxially centered surrounding the core yarn, a nominal average outerdiameter of the coated yarn is up to about 1.0 millimeter, the firstcoating has an average radial coating thickness of about 50 micrometersto about 200 micrometers, and wherein, in the thermoformed network, thefirst polymeric composition consolidating the thermoformed network ofyarns is the re-flowed and re-solidified product of the first polymericcomposition of the first coating of the first coated yarn; wherein, inthe first coated yarn, the first thermoplastic composition has a firstmelting temperature greater than about 110 degrees Celsius and less thanabout 190 degrees Celsius, the second polymeric composition of the coreyarn has a second deformation temperature, and the second deformationtemperature is at least 50 degrees Celsius greater than the firstmelting temperature of the first polymeric composition; wherein a firstside of the thermoformed network defines at least a portion of a surfaceof the outsole configured to be externally-facing or ground-facing orground-contacting when the outsole is part of a finished article offootwear.
 2. The outsole of claim 1, wherein the thermoformed networkdefines at least a portion of a surface of the outsole configured to beground-contacting when the outsole is part of a finished article offootwear, and the thermoformed network further comprises a layer of athird polymeric composition, wherein the third polymeric composition isa thermoplastic elastomeric composition comprising thermoplasticelastomeric polyurethane; wherein a first side of the layer defines thesurface of the outsole configured to be ground-contacting when theoutsole is part of a finished article of footwear, and a second side ofthe yarn opposite the first side is thermally bonded to a first side ofthe textile via the first polymeric composition of the textile.
 3. Theoutsole of claim 2, wherein the layer of the third polymeric compositionis an extruded layer or an injection molded layer or a film layer. 4.The outsole of claim 2, wherein the thermoplastic elastomericpolyurethane of the first polymeric composition and the thermoplasticelastomeric polyurethane of the third polymeric component each have thesame chemical structure, or the first polymeric composition and thethird polymeric composition each have melting temperatures within about10 degrees Celsius of each other, or both.
 5. The outsole of claim 2,wherein the layer of the third polymeric composition has a thickness offrom about 0.1 millimeter to about 5 millimeters.
 6. The outsole ofclaim 1, wherein the textile is bonded to a foam sole component.
 7. Theupper of claim 1, wherein the thermoplastic elastomeric polyurethane isa thermoplastic elastomeric polyester polyurethane, a thermoplasticpolyether polyurethane, or any combination thereof.
 8. The upper ofclaim 1, wherein the thermoplastic elastomeric polyurethane comprises anaromatic polyester thermoplastic elastomeric polyurethane, an aliphaticpolyester thermoplastic elastomeric polyurethane, or a combinationthereof.
 9. The outsole of claim 1, wherein the first polymericcomposition has a melt flow index of about 2 grams/10 minutes to about50 grams/10 minutes at 160 degrees Celsius using a test weight of 2.16kilograms as determined using ASTM D1238-13, or a melt flow indexgreater than about 2 grams/10 minutes at 190 degrees centigrade or 200degrees Celsius when using a test weight of 10 kilograms as determinedusing the Melt Flow Index Test.
 10. The outsole of claim 1, wherein thefirst core yarn comprises a polyester or a polyamide having a lineardensity from about 100 denier to about 300 denier.
 11. The outsole ofclaim 1, wherein the first polymeric composition or the third polymericcomposition has a dry dynamic coefficient of friction (COF) of greaterthan 1.0 as determined against dry smooth concrete using the Coefficientof Friction Test.
 12. The outsole of claim 1, wherein the firstpolymeric composition or the third polymeric composition has a wetdynamic COF of greater than 0.3 as determined against wet smoothconcrete using the Coefficient of Friction Test.
 13. The outsole ofclaim 1, wherein, for the first polymeric composition or the thirdpolymeric composition, the difference between the wet dynamiccoefficient of friction and the dry dynamic coefficient of friction isless than 40 percent as determined using the Coefficient of FrictionTest.
 14. The outsole of claim 1, wherein, for the thermoformed network,the difference between the dry dynamic coefficient of friction and thewet coefficient of friction is less than 55 percent as determined usingthe Coefficient of Friction Test.
 15. The outsole of claim 1, whereinthe difference between the static coefficient of friction of the drysurface and the wet surface of the textile is less than 40 percent asdetermined using the Coefficient of Friction Test
 16. The outsole ofclaim 1, wherein the textile has a dry shoe traction of greater than 6and a wet shoe traction of greater than 5 as determined using the Methodto Determine Whole Shoe Traction after Biomechanical Abrasion.
 17. Theoutsole of claim 1, wherein the textile has an abrasion loss of lessthan 0.50 cubic centimeters lost after 3,000 cycles as determined usingthe Akron Abrasion Test.
 18. The outsole of claim 1, wherein the textilehas a abrasion loss of less than 0.30 cubic centimeters lost asdetermined using the DIN Abrasion Test.